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IW Series Industrial Wireless Measurement System

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IW Series Industrial Wireless Measurement System

A complete wireless sensor and receiver system for use in industrial applications to communicate with a suite of battery powered measurement devices and send readings via analog signals, USB, RS232, RS485, Ethernet or mobile phone network.

Contents

Product Features

  • Battery powered wireless sensors
  • Measure temperature, pressure, humidity, tilt, potentiometer & analog signals
  • Receivers to manage polling each wireless sensor
  • Send channel data via analog signal, digital coms or mobile network
  • Software for managing all system devices, configuration and setup

IWT Series Wireless Sensor Transmitters

IWR Series Wireless Receivers

Applications

Irrigation rig monitoring

Wireless current sensors can be used to monitor the current taken by motors driving large scale irrigation rigs. This information can be used to check for overloaded motors, which can be caused by flat tires on the wheels fitted to them.  

The wireless current sensors are typically installed on the power lines leading to the motors. The sensors transmit the current data wirelessly to a central monitoring station. The monitoring station can then analyze the data and identify any potential problems.  

This application can help to prevent damage to the motors and ensure the efficient operation of the irrigation system.  

Here are some additional details about this application:

  • The wireless current sensors can be powered by batteries or by the power lines themselves.
  • The sensors can transmit data over a variety of wireless protocols, including Wi-Fi, Bluetooth, and cellular.
  • The monitoring station can be located on-site or off-site.
  • The system can be configured to generate alarms if the current exceeds a certain threshold.
  • The system can also be used to track the energy consumption of the irrigation system.

This application is a good example of how wireless sensor systems can be used to improve the efficiency and reliability of industrial processes.

Railway embankment monitoring

Railway embankment monitoring is a critical safety application that is seeing increased use of wireless sensor systems. Traditional methods of monitoring embankment stability often involve manual inspections and measurements, which can be time-consuming, costly, and potentially dangerous for personnel. Wireless sensor systems offer a more efficient and safer solution.  

In this application, Microelectromechanical systems (MEMS) inclinometers are buried within the embankment to monitor movement. MEMS inclinometers are small, low-cost sensors that measure the angle of inclination with respect to gravity. They are ideal for this application due to their size, accuracy, and ability to withstand harsh environments.  

The wireless sensors transmit the inclination data to a central monitoring station, where it can be analyzed for trends and anomalies. This allows for early detection of potential slope instability or movement, enabling timely intervention and preventative measures to be taken.

The benefits of using wireless sensor systems for railway embankment monitoring include:

  • Improved safety: Reduced need for manual inspections in potentially hazardous areas.  
  • Early detection of problems: Continuous monitoring allows for early identification of potential issues, preventing catastrophic failures.  
  • Cost-effectiveness: Reduced labor costs and increased efficiency compared to traditional methods.  
  • Remote monitoring: Data can be accessed from anywhere, allowing for better decision-making.

Wireless sensor systems are proving to be a valuable tool for railway embankment monitoring, improving safety and efficiency while reducing costs.

Monitoring of CNC machine fixtures

Ensuring the precise and secure clamping of workpieces is crucial in CNC machining operations. Wireless sensors are increasingly being embedded into fixtures to monitor hydraulic clamping pressure, providing real-time data and alerts on clamping conditions.

How it Works

  • Embedded Sensors: Small, wireless pressure sensors are integrated directly into the fixture, close to the hydraulic clamping mechanism. These sensors continuously measure the hydraulic pressure applied to the workpiece.
  • Wireless Data Transmission: The pressure data is transmitted wirelessly to a receiver or gateway, eliminating the need for cumbersome wires and connectors.
  • Monitoring and Alerts: The received data is monitored for any deviations from the specified clamping pressure. If a significant change or drop in pressure is detected, an alarm is triggered, notifying operators of a potential clamping issue.

Benefits

  • Improved Part Quality: Consistent clamping pressure ensures accurate machining and reduces the risk of scrapped parts due to workpiece movement or vibration.
  • Increased Productivity: Early detection of clamping problems minimizes downtime and allows for prompt corrective action.
  • Enhanced Safety: Prevents potential accidents caused by improperly clamped workpieces.
  • Reduced Costs: Minimizes scrap, rework, and machine downtime, leading to cost savings.
  • Predictive Maintenance: Monitoring clamping pressure trends can help predict potential fixture wear or hydraulic system issues, enabling proactive maintenance.

Use Cases

This application is particularly valuable in high-precision machining environments where even slight variations in clamping pressure can significantly impact part quality. Industries such as aerospace, medical device manufacturing, and automotive often utilize this technology to ensure the reliability and accuracy of their machining processes.

Solar farm high terminal monitoring

Solar farms are becoming increasingly common as the world transitions to cleaner energy sources. However, a common issue that can affect the efficiency and safety of solar farms is the development of high-resistance joints in the DC (direct current) combiner boxes and substations. These high-resistance joints can lead to energy losses and even pose a fire hazard.

Traditional methods of detecting high-resistance joints often involve manual inspections using thermal cameras or contact probes, which can be time-consuming and inefficient. Wireless sensor systems offer a more effective and convenient solution for continuous monitoring.

Wireless Monitoring System

  • Digital Temperature ICs: Small, wireless temperature sensors equipped with digital temperature integrated circuits (ICs) are strategically placed in the combiner boxes and substations. These sensors provide accurate temperature readings at critical connection points.
  • Wireless Communication: The temperature data is transmitted wirelessly to a central monitoring station, eliminating the need for extensive wiring.
  • Real-time Monitoring and Alerts: The monitoring station continuously analyzes the temperature data. If a significant temperature rise is detected at a joint, indicating a high-resistance connection, an alarm is triggered, notifying maintenance personnel of the potential problem.

Benefits

  • Early Problem Detection: Continuous monitoring allows for early detection of high-resistance joints, preventing potential energy losses and safety hazards.
  • Reduced Maintenance Costs: Prevents costly repairs and downtime by identifying problems before they escalate.
  • Improved Safety: Reduces the risk of fire hazards associated with overheating connections.
  • Increased Efficiency: Helps maintain optimal energy output by minimizing losses due to high-resistance joints.
  • Remote Monitoring: Allows for convenient monitoring of multiple combiner boxes and substations from a central location.

Use Cases

This application is essential for ensuring the safe and efficient operation of solar farms of all sizes. By providing early detection of high-resistance joints, wireless sensor systems help maximize energy production and minimize downtime.

Motor condition monitoring in industrial settings

In today’s industrial landscape, maintaining the health and efficiency of electric motors is critical for ensuring smooth production processes and minimizing downtime. Traditional motor monitoring techniques often involve periodic manual inspections or wired sensors, which can be time-consuming, expensive, and limited in scope. Wireless sensor systems offer a more advanced and comprehensive solution for continuous motor condition monitoring.

Wireless Motor Condition Monitoring

  • Sensor Integration: Wireless sensors, such as vibration sensors, current sensors, and temperature sensors, are strategically placed on the motor or its housing. These sensors continuously collect data on various motor parameters.
  • Wireless Data Transmission: The sensor data is transmitted wirelessly to a central monitoring station or gateway, eliminating the need for complex wiring and reducing installation costs.
  • Data Analysis and Diagnostics: Advanced algorithms analyze the collected data to detect anomalies and identify potential issues such as:
    • High Resistance Joints (HRJs): These are poor electrical connections that can lead to overheating and motor failure. Wireless sensors can detect HRJs by monitoring temperature changes at the motor terminals.
    • Phase Imbalance: This occurs when the electrical currents in the three phases of a motor are unequal, leading to reduced efficiency and potential damage. Wireless current sensors can accurately measure and monitor phase currents.
    • Increased Load Conditions: Overloading a motor can cause it to overheat and fail prematurely. Wireless sensors can monitor motor load by measuring parameters such as vibration, current, and temperature.
  • Real-time Alerts and Notifications: If any abnormal conditions are detected, the system triggers alerts and notifies maintenance personnel, enabling prompt corrective action.

Benefits

  • Enhanced Reliability: Continuous monitoring helps identify potential problems early on, preventing unexpected motor failures and reducing downtime.
  • Improved Efficiency: Detecting and addressing issues like phase imbalance and HRJs helps optimize motor performance and reduce energy consumption.
  • Extended Motor Lifespan: Early detection of problems and proactive maintenance can significantly extend the lifespan of motors.
  • Reduced Maintenance Costs: Avoids costly repairs and downtime by addressing issues before they escalate.
  • Increased Safety: Helps prevent safety hazards associated with motor malfunctions.
  • Scalability: Wireless systems can easily monitor hundreds or even thousands of motors across a facility.

Use Cases

Wireless motor condition monitoring is applicable across a wide range of industries, including manufacturing, mining, oil and gas, and power generation. It is particularly valuable in applications with a large number of critical motors where continuous monitoring is essential for ensuring operational efficiency and safety.

Log loader load weighing

In the forestry industry, accurately weighing log loads is crucial for managing inventory, optimizing transportation, and ensuring fair trade. Traditional methods of weighing log loaders often involve dedicated weighbridges or load cells installed on the loader itself. These methods can be expensive, time-consuming, and may require specialized equipment. Wireless sensor systems offer a more flexible and cost-effective alternative.

Wireless Load Weighing System

  • Hydraulic Pressure Sensing: Wireless pressure sensors are integrated into the hydraulic system of the log loader. These sensors measure the hydraulic pressure, which is directly proportional to the weight of the logs being lifted.
  • Wireless Data Transmission: The pressure data is transmitted wirelessly to a receiver or display unit located in the loader cabin or a nearby vehicle.
  • Weight Calculation and Display: The receiver unit converts the pressure readings into weight measurements using pre-calibrated algorithms. The weight information is then displayed in real-time, allowing the operator to monitor the load.

Benefits

  • Increased Efficiency: Eliminates the need for time-consuming trips to weighbridges, improving productivity.
  • Cost Savings: Reduces the need for dedicated weighing equipment and infrastructure.
  • Improved Accuracy: Provides real-time weight measurements, ensuring accurate load management.
  • Flexibility: Allows for weighing in various locations, increasing operational flexibility.
  • Data Logging: Many systems can log weight data for record-keeping and analysis.

Use Cases

This application is particularly beneficial in remote logging operations where access to weighbridges is limited. It allows for on-site weighing, improving efficiency and reducing transportation costs.

Rotating oven temperature measurement

Rotating ovens are used in various industrial processes, such as food production, chemical processing, and manufacturing. Accurately measuring the temperature inside these rotating ovens is crucial for ensuring product quality and process efficiency. However, traditional methods of temperature measurement using wired sensors can be problematic due to the continuous rotation of the oven. Slip rings, which are electromechanical devices used to transmit power and data from a stationary to a rotating structure, have been commonly employed for this purpose. However, slip rings are prone to wear and tear, leading to unreliable data and frequent maintenance. Wireless thermocouple transmitters offer a more robust and reliable solution for rotating oven temperature measurement.

Wireless Temperature Measurement System

  • Thermocouple Transmitters: Thermocouples, which are widely used temperature sensors, are attached to wireless transmitters. These transmitters are mounted inside the rotating oven, eliminating the need for slip rings.
  • Wireless Data Transmission: The temperature data from the thermocouples is converted into a wireless signal and transmitted to a receiver located outside the oven.
  • Real-time Monitoring and Control: The receiver displays the temperature readings in real-time, allowing operators to monitor the oven temperature and make necessary adjustments to the process.

Benefits

  • Improved Reliability: Eliminates the reliance on slip rings, which are prone to failure, resulting in more reliable temperature data.
  • Reduced Maintenance: Reduces maintenance requirements and downtime associated with slip ring replacement and repair.
  • Increased Accuracy: Wireless thermocouple transmitters can provide highly accurate temperature measurements.
  • Enhanced Safety: Wireless systems eliminate the need for electrical connections across rotating parts, improving safety.
  • Cost Savings: Reduces maintenance costs and potential production losses due to unreliable temperature data.

Use Cases

This application is particularly beneficial in industries where continuous and reliable temperature monitoring is critical, such as food processing, pharmaceuticals, and materials manufacturing.

Vibration monitoring in mining operations

Vibration monitoring plays a crucial role in ensuring the safety and efficiency of heavy machinery used in mining operations, particularly in challenging environments like iron ore and coal mines. Traditional methods of vibration monitoring often involve wired sensors and data acquisition systems, which can be difficult and expensive to install and maintain in harsh mining conditions. Wireless sensor systems offer a more practical and cost-effective solution for continuous vibration monitoring.

Wireless Vibration Monitoring System

  • Industrial Accelerometers: Industrial-grade accelerometers, which measure acceleration and vibration, are attached to critical components of mining machinery, such as haul trucks, excavators, and conveyor belts. These accelerometers are integrated with wireless transmitters.
  • Wireless Data Transmission: The vibration data from the accelerometers is converted into a wireless signal and transmitted to a receiver located in a control room or on a mobile device.
  • Real-time Analysis and Diagnostics: Advanced software analyzes the vibration data to detect anomalies and identify potential problems, such as bearing wear, gear damage, or structural fatigue.
  • Alerts and Predictive Maintenance: The system triggers alerts if abnormal vibration levels are detected, enabling timely maintenance and preventing catastrophic failures. This predictive maintenance approach helps minimize downtime and extend the lifespan of expensive mining equipment.

Benefits

  • Improved Safety: Helps prevent accidents and equipment failures caused by undetected vibration problems.
  • Reduced Downtime: Enables proactive maintenance, minimizing costly downtime and production losses.
  • Extended Equipment Lifespan: Early detection of vibration issues can prevent further damage and extend the life of mining machinery.
  • Cost Savings: Reduces maintenance costs and avoids expensive repairs by addressing problems early on.
  • Enhanced Productivity: Ensures optimal performance of mining equipment, improving overall productivity.
  • Remote Monitoring: Allows for convenient monitoring of equipment in remote or hazardous areas.

Use Cases

This application is essential for ensuring the safe and efficient operation of mining equipment in harsh environments. It is particularly valuable in large-scale mining operations where continuous monitoring of numerous machines is crucial for maintaining productivity and safety.

Sludge depth monitoring in waste treatment works

Maintaining an optimal sludge depth in wastewater treatment tanks is crucial for efficient treatment processes. Traditionally, sludge depth measurement has relied on mechanical or electromechanical systems, often involving moving parts like floats or probes connected to a display or control unit via slip rings. These systems can be prone to wear and tear, requiring frequent maintenance and potentially leading to inaccurate measurements. Wireless sensor systems offer a more reliable and maintenance-free solution for sludge depth monitoring.

Wireless Sludge Depth Monitoring System

  • Ultrasonic Sensors: Wireless ultrasonic sensors are typically installed above the wastewater treatment tank. These sensors emit ultrasonic pulses and measure the time it takes for the pulses to reflect back from the sludge surface, providing accurate and continuous sludge depth measurement.
  • Wireless Data Transmission: The depth data is transmitted wirelessly to a receiver or monitoring station, eliminating the need for slip rings and associated wiring.
  • Real-time Monitoring and Control: The received data is displayed in real-time, allowing operators to monitor sludge levels and make necessary adjustments to the treatment process.

Benefits

  • Improved Reliability: Eliminates the reliance on slip rings and mechanical components, reducing maintenance requirements and improving reliability.
  • Maintenance-Free Operation: Wireless sensors require minimal maintenance, reducing downtime and operational costs.
  • Increased Accuracy: Ultrasonic sensors provide accurate and continuous sludge depth measurement.
  • Enhanced Safety: Wireless systems eliminate the need for electrical connections across rotating or moving parts, improving safety.
  • Cost Savings: Reduces maintenance costs and potential process disruptions due to inaccurate measurements.

Use Cases

This application is essential for optimizing wastewater treatment processes and ensuring compliance with environmental regulations. Wireless sludge depth monitoring is particularly beneficial in large treatment plants where continuous monitoring of multiple tanks is crucial for efficient operation.

Protecting public art with wireless tamper monitoring

Public sculptures and art installations are often vulnerable to vandalism, theft, and accidental damage. Traditional security measures, such as fences and surveillance cameras, can be expensive, intrusive, and may not provide comprehensive protection. Wireless sensor systems offer a discreet and effective solution for monitoring sculptures and detecting tampering attempts.

Wireless Sculpture Monitoring System

  • Vibration Sensors: Wireless vibration sensors are strategically placed on the sculpture or its base. These sensors are designed to detect unusual vibrations or movements that may indicate tampering, attempted theft, or accidental impact.
  • Wireless Communication: The vibration data is transmitted wirelessly to a central monitoring station or a security personnel’s mobile device.
  • Real-time Alerts: If the sensors detect significant vibrations or movements exceeding a pre-set threshold, an alarm is triggered, and an SMS message is sent to alert security personnel or designated contacts.
  • GPS Tracking (Optional): Some systems may also include GPS tracking capabilities, allowing for the location of the sculpture to be monitored in real-time, which can be crucial in case of theft.

Benefits

  • Early Detection: Provides immediate notification of tampering attempts, enabling rapid response and minimizing potential damage or loss.
  • Deterrence: The presence of a monitoring system can act as a deterrent to vandals and thieves.
  • Discreet Protection: Wireless sensors can be small and easily concealed, preserving the aesthetic integrity of the artwork.
  • Remote Monitoring: Allows for monitoring of sculptures in various locations, including outdoor and remote areas.
  • Cost-Effectiveness: Can be a more cost-effective solution compared to traditional security measures.

Use Cases

This application is suitable for protecting valuable sculptures and art installations in public spaces, museums, galleries, and private collections.

Piling rig concrete pressure monitoring

In construction projects involving deep foundations, piling rigs are used to drive piles into the ground to support structures. During the piling process, concrete is pumped through a pipe to the bottom of the pile to form the foundation. Monitoring the concrete pressure at the “swan neck,” which is the top part of the piling rig where the concrete pipe bends, is crucial to detect any blockages or backups in the concrete flow. Traditionally, this monitoring has relied on wired pressure sensors connected to a display unit. However, wireless sensor systems offer a more convenient and reliable solution for piling rig concrete pressure monitoring.

Wireless Concrete Pressure Monitoring System

  • Wireless Pressure Sensors: Wireless pressure sensors are installed at the swan neck of the piling rig, directly measuring the concrete pressure. These sensors are designed to withstand the harsh conditions of a construction site.
  • Wireless Data Transmission: The pressure data is transmitted wirelessly to a receiver unit located in the piling rig cabin or a nearby control station.
  • Real-time Monitoring and Alerts: The receiver unit displays the concrete pressure in real-time, allowing the operator to monitor the piling process. If the pressure exceeds a pre-set threshold or drops unexpectedly, indicating a potential blockage, an alarm is triggered, alerting the operator to take corrective action.

Benefits

  • Improved Safety: Helps prevent accidents and damage to the piling rig caused by concrete backups or blockages.
  • Enhanced Efficiency: Allows for continuous monitoring of the concrete pressure, ensuring a smooth and efficient piling process.
  • Reduced Downtime: Early detection of concrete flow problems minimizes downtime and delays in the construction project.
  • Cost Savings: Prevents costly repairs and rework by addressing concrete flow issues promptly.
  • Wireless Convenience: Eliminates the need for cumbersome wires and cables, improving safety and maneuverability on the construction site.

Use Cases

This application is essential for ensuring the safe and efficient operation of piling rigs in various construction projects, including bridges, high-rise buildings, and infrastructure development.

Car all-over water spray pressure monitoring

In automotive manufacturing, ensuring the proper application of water sprays during various stages of production is crucial for achieving optimal quality and efficiency. These sprays are used for processes such as underbody cleaning, overbody rinsing, and paint booth applications. Maintaining consistent and accurate water spray pressure is essential for achieving the desired cleaning or coating results. Traditionally, monitoring water spray pressure has relied on manual gauges or wired sensors, which can be cumbersome and limit real-time visibility. Wireless sensor systems offer a more convenient and effective solution for monitoring water spray pressure throughout the vehicle production process.

Wireless Water Spray Pressure Monitoring System

  • Wireless Pressure Sensors: Compact, wireless pressure sensors are installed at critical points in the water spray system, such as the underbody spray nozzles, overbody spray headers, and paint booth manifolds. These sensors are designed to withstand the harsh conditions of an automotive manufacturing environment.
  • Wireless Data Transmission: The pressure data from the sensors is transmitted wirelessly to a central monitoring station or a mobile device, providing real-time visibility into the spray pressure at various locations.
  • Real-time Monitoring and Control: The monitoring station displays the pressure readings in real-time, allowing operators to monitor the spray pressure and make necessary adjustments to ensure optimal performance. The system can also be configured to trigger alarms if the pressure deviates from pre-set limits, enabling prompt corrective action.

Benefits

  • Improved Quality: Consistent and accurate water spray pressure ensures optimal cleaning and coating results, improving the quality of the finished vehicle.
  • Increased Efficiency: Real-time monitoring allows for quick identification and resolution of pressure-related issues, minimizing production downtime.
  • Reduced Water Consumption: Optimizing spray pressure helps reduce water usage and minimize waste.
  • Data Logging and Analysis: The system can log pressure data for analysis and process optimization, identifying trends and potential areas for improvement.
  • Wireless Convenience: Eliminates the need for extensive wiring, improving safety and flexibility in the manufacturing environment.

Use Cases

This application is valuable in various stages of automotive manufacturing, including:

  • Underbody Cleaning: Ensuring thorough cleaning of the vehicle underbody to remove contaminants and prepare for further processing.
  • Overbody Rinsing: Providing consistent rinsing of the vehicle body to remove residual cleaning agents or paint particles.
  • Paint Booth Applications: Maintaining precise spray pressure for optimal paint application and minimizing overspray.

Ensuring optimal office environments with wireless temperature and humidity monitoring

Maintaining a comfortable and healthy indoor environment is crucial in commercial offices. Temperature and relative humidity (RH) levels play a significant role in occupant comfort, productivity, and overall well-being. During the HVAC (Heating, Ventilation, and Air Conditioning) installation acceptance period, it is essential to verify that the system is functioning correctly and providing the desired environmental conditions. Wireless sensor systems offer a convenient and effective solution for monitoring temperature and RH levels in offices during this critical phase.

Wireless Temperature and RH Monitoring System

  • Wireless Sensors: Compact, wireless sensors that measure both temperature and relative humidity are strategically placed throughout the office space. These sensors are designed to blend discreetly with the office environment.
  • Wireless Data Transmission: The temperature and RH data from the sensors is transmitted wirelessly to a central monitoring station or a mobile device, providing real-time visibility into the environmental conditions.
  • Real-time Monitoring and Reporting: The monitoring station displays the temperature and RH readings in real-time, allowing facility managers or HVAC technicians to monitor conditions throughout the office. The system can also generate reports that document the environmental conditions over time, which can be valuable for demonstrating compliance with building codes and industry standards.

Benefits

  • Verification of HVAC Performance: Provides accurate and comprehensive data on temperature and RH levels, allowing for verification that the HVAC system is meeting the specified requirements.
  • Identification of Problem Areas: Helps identify any areas within the office where temperature or humidity levels are outside the desired range, enabling targeted adjustments to the HVAC system.
  • Improved Occupant Comfort: Ensures a comfortable and productive work environment for occupants by maintaining optimal temperature and humidity levels.
  • Energy Efficiency: Helps optimize HVAC operation by identifying areas where adjustments can be made to reduce energy consumption without compromising comfort.
  • Wireless Convenience: Eliminates the need for extensive wiring, minimizing disruption to the office environment during the monitoring period.

Use Cases

This application is particularly valuable during the HVAC installation acceptance period in new or renovated office buildings. It can also be used for ongoing monitoring of environmental conditions to ensure occupant comfort and optimize HVAC performance.

Wireless fire testing with long-range thermocouple transmitters

Fire testing is a critical process for evaluating the fire resistance of building materials and structures. During fire tests, accurately monitoring the internal temperature of the building or structure is essential for assessing its performance and ensuring safety. Traditionally, this has involved using long thermocouple wires routed throughout the test structure and connected to a data acquisition system outside the fire test chamber. However, this approach can be cumbersome, time-consuming, and potentially compromise the integrity of the test structure due to the numerous wire penetrations. Wireless thermocouple transmitters offer a more efficient and reliable solution for fire temperature monitoring.

Wireless Fire Temperature Monitoring System

  • Long-Range Thermocouple Transmitters: Thermocouples, which are widely used temperature sensors, are attached to wireless transmitters specifically designed for long-range operation. These transmitters are placed at strategic locations within the test structure.
  • Wireless Data Transmission: The temperature data from the thermocouples is converted into a wireless signal and transmitted to a receiver located outside the fire test chamber. The use of long-range wireless technology allows for reliable data transmission even through thick walls and obstacles.
  • Real-time Monitoring and Data Logging: The receiver displays the temperature readings in real-time, allowing engineers and researchers to monitor the temperature distribution within the test structure during the fire test. The system can also log the temperature data for further analysis and reporting.

Benefits

  • Simplified Setup: Eliminates the need for extensive thermocouple wiring, reducing setup time and complexity.
  • Reduced Intrusiveness: Minimizes the number of penetrations required in the test structure, preserving its integrity and reducing the risk of fire propagation.
  • Reliable Data Transmission: Long-range wireless technology ensures reliable data transmission even in challenging fire test environments.
  • Enhanced Safety: Wireless systems eliminate the need for electrical connections across fire barriers, improving safety for personnel.
  • Cost-Effectiveness: Reduces labor costs and potential damage to the test structure associated with traditional wired thermocouple installations.

Use Cases

This application is valuable in various fire testing scenarios, including:

  • Building Materials Testing: Evaluating the fire resistance of walls, floors, and other building components.
  • Structural Fire Testing: Assessing the performance of structural elements, such as beams and columns, under fire conditions.
  • Fire Research: Conducting research on fire dynamics and the behavior of materials in fire.

Precision winemaking with wireless temperature monitoring

In the world of winemaking, temperature control during fermentation is critical for achieving the desired flavor profile and quality of the final product. Traditional methods of temperature monitoring often involve manual measurements or wired sensors, which can be labor-intensive and limit real-time visibility into the fermentation process. Wireless sensor systems offer a more convenient and precise solution for monitoring the temperature of fermenting wine inside winery vats.

Wireless Wine Fermentation Monitoring System

  • Wireless Temperature Sensors: Submersible, wireless temperature sensors are placed directly inside the fermentation vats. These sensors are designed to withstand the acidic environment and provide accurate temperature readings.
  • Wireless Data Transmission: The temperature data from the sensors is transmitted wirelessly to a central monitoring station, a computer, or a mobile device, providing winemakers with real-time access to the fermentation temperature.
  • Real-time Monitoring and Control: The monitoring system displays the temperature readings in real-time, allowing winemakers to closely monitor the fermentation process and make necessary adjustments to maintain the optimal temperature range. Some systems may also allow for remote control of cooling or heating systems to precisely regulate the fermentation temperature.

Benefits

  • Improved Wine Quality: Precise temperature control during fermentation leads to better flavor development, color stability, and overall wine quality.
  • Reduced Spoilage: Maintaining the optimal temperature range helps prevent the growth of unwanted microorganisms that can spoil the wine.
  • Increased Efficiency: Wireless monitoring eliminates the need for manual temperature checks, freeing up winemakers’ time for other tasks.
  • Data Logging and Analysis: The system can log temperature data throughout the fermentation process, providing valuable insights for analyzing and optimizing future winemaking practices.
  • Remote Monitoring: Allows winemakers to monitor the fermentation process from anywhere, providing greater flexibility and control.

Use Cases

This application is suitable for wineries of all sizes, from small boutique wineries to large commercial operations. Wireless temperature monitoring can be used for various types of wine and fermentation vessels, including stainless steel tanks, oak barrels, and concrete vats.

Wellhead pressure monitoring system

Monitoring wellhead pressure is crucial in oil and gas production, as well as in water and geothermal wells. Accurate pressure measurements provide valuable insights into reservoir conditions, wellbore integrity, and production optimization. Traditional methods of wellhead pressure monitoring often involve manual gauges or wired pressure sensors connected to a local display or control system. However, these methods can be limited in terms of real-time data access, remote monitoring capabilities, and automation potential. Wireless sensor systems offer a more advanced and efficient solution for wellhead pressure monitoring.

Wireless Wellhead Pressure Monitoring System

  • Wireless Pressure Sensors: Wireless pressure sensors, specifically designed for harsh environments, are installed directly onto the wellhead. These sensors are typically housed in rugged enclosures and may include features such as corrosion resistance and explosion protection.
  • Wireless Data Transmission: The pressure data from the sensors is transmitted wirelessly to a central monitoring station, a remote control room, or a mobile device. Various wireless communication technologies can be used, including cellular, radio, or satellite, depending on the location and accessibility of the wellhead.
  • Real-time Monitoring and Analysis: The monitoring system provides real-time access to wellhead pressure data, allowing operators to continuously monitor well performance and identify any potential issues. Advanced analytics and visualization tools can be used to analyze pressure trends, predict production decline, and optimize well management strategies.
  • Alerts and Automation: The system can be configured to trigger alerts if pressure readings deviate from pre-set limits, indicating potential problems such as leaks, blockages, or equipment malfunctions. This enables prompt corrective action and helps prevent costly downtime or safety hazards. Additionally, wireless pressure data can be integrated with automated control systems to optimize well production, such as adjusting flow rates or shutting down wells remotely based on pressure conditions.

Benefits

  • Improved Safety: Continuous pressure monitoring helps identify potential problems early on, preventing well blowouts, leaks, and other safety hazards.
  • Enhanced Production Efficiency: Real-time pressure data and analytics enable optimization of well production, maximizing output and minimizing downtime.
  • Reduced Operational Costs: Wireless systems eliminate the need for extensive wiring and manual data collection, reducing installation and maintenance costs.
  • Remote Monitoring and Control: Allows for monitoring and managing wellhead pressure from anywhere, providing greater flexibility and operational efficiency.
  • Environmental Protection: Early detection of leaks and other anomalies helps prevent environmental damage and ensures compliance with regulations.

Use Cases

Wireless wellhead pressure monitoring systems are applicable to various types of wells, including:

  • Oil and Gas Wells: Monitoring production pressures, detecting leaks, and optimizing production rates.
  • Water Wells: Monitoring water levels, detecting pump failures, and managing water resources.
  • Geothermal Wells: Monitoring reservoir pressures and optimizing energy production.

Ensuring excavation safety with wireless monitoring systems

Large-scale excavations, such as those for building foundations, tunnels, or underground infrastructure, require careful monitoring to ensure stability and prevent collapses. The support structures, typically consisting of struts or bracing systems, play a crucial role in maintaining the excavation’s integrity. Monitoring the level and force on these struts is essential for identifying potential weaknesses or excessive loads that could lead to failure. Traditional monitoring methods often involve manual measurements and visual inspections, which can be time-consuming, subjective, and potentially dangerous for personnel. Wireless sensor systems offer a more efficient, accurate, and safe solution for excavation monitoring.

Wireless Excavation Monitoring System

  • Wireless Level Sensors: Wireless inclinometers or tilt sensors are installed on the struts to measure their level or inclination. These sensors provide data on any changes in the strut’s position, indicating potential movement or deformation of the excavation support system.
  • Wireless Load Cells: Wireless load cells are integrated into the struts to measure the force or load they are carrying. This data provides insights into the stress on the support system and helps identify areas where the excavation may be exerting excessive pressure.
  • Wireless Data Transmission: The data from the level sensors and load cells is transmitted wirelessly to a central monitoring station, a mobile device, or a cloud-based platform, providing real-time visibility into the excavation’s stability.
  • Real-time Monitoring and Alerts: The monitoring system displays the level and force measurements in real-time, allowing engineers and construction managers to continuously assess the excavation’s condition. The system can also be configured to trigger alerts if measurements exceed pre-set thresholds, indicating potential instability or overload. This enables prompt intervention and preventative measures to be taken, ensuring the safety of workers and the integrity of the project.

Benefits

  • Enhanced Safety: Continuous monitoring and real-time alerts help prevent excavation collapses and protect workers from potential hazards.
  • Improved Accuracy: Wireless sensors provide objective and accurate data on strut level and force, eliminating the subjectivity of manual measurements.
  • Increased Efficiency: Wireless systems streamline the monitoring process, reducing the need for time-consuming manual inspections.
  • Remote Monitoring: Allows for monitoring of excavations in remote or hazardous areas, improving safety and accessibility.
  • Data Logging and Analysis: The system can log data over time, providing valuable insights for analyzing excavation behavior and optimizing future projects.

Use Cases

Wireless excavation monitoring systems are applicable to various types of excavation projects, including:

  • Building Foundations: Monitoring the stability of deep excavations for high-rise buildings or underground structures.
  • Tunnel Construction: Monitoring the support systems in tunnels to prevent collapses and ensure worker safety.
  • Road and Rail Excavations: Monitoring the stability of excavations for road or rail infrastructure projects.
  • Mining Operations: Monitoring the stability of open-pit mines or underground excavations.

Optimizing water usage in quarries with wireless monitoring

Water management is a crucial aspect of quarry operations, impacting productivity, environmental compliance, and overall sustainability. Quarries use water for various purposes, including dust suppression, material processing, and equipment washing. Accurately monitoring water usage is essential for optimizing consumption, identifying leaks or inefficiencies, and ensuring responsible water management practices. Traditional methods of water monitoring often involve manual meter readings or wired data acquisition systems, which can be time-consuming, labor-intensive, and limited in terms of real-time data access. Wireless sensor systems offer a more efficient and comprehensive solution for monitoring water usage in quarries.

Wireless Quarry Water Usage Monitoring System

  • Wireless Pulse Meters: Wireless pulse meters are installed on water meters at various points throughout the quarry, such as the main water intake, individual process lines, and equipment wash stations. These meters generate pulses proportional to the volume of water flowing through them.
  • Wireless Data Transmission: The pulse data from the meters is transmitted wirelessly to a central monitoring station, a control room, or a mobile device. The wireless communication technology used will depend on the size and layout of the quarry, with options including radio frequency, cellular, or even satellite communication for remote locations.
  • Real-time Monitoring and Analysis: The monitoring system provides real-time visibility into water usage across the quarry, allowing operators to track consumption patterns, identify peak demand periods, and detect any unusual water usage that may indicate leaks or inefficiencies. Data visualization tools can be used to display water usage trends, compare consumption across different areas of the quarry, and generate reports for analysis and decision-making.
  • Alerts and Automation: The system can be configured to trigger alerts if water usage exceeds pre-set thresholds or if unusual consumption patterns are detected. This enables prompt investigation and corrective action, minimizing water waste and potential environmental impact. Additionally, wireless water usage data can be integrated with automated control systems to optimize water management practices, such as adjusting irrigation schedules or automatically shutting off water supply to certain areas during periods of inactivity.

Benefits

  • Sustainable Water Management: Promotes responsible water use by providing accurate data on consumption patterns and enabling optimization strategies.
  • Leak Detection and Prevention: Helps identify leaks promptly, minimizing water loss and potential environmental damage.
  • Improved Efficiency: Real-time data and analytics enable optimization of water-dependent processes, improving overall operational efficiency.
  • Reduced Costs: Minimizes water waste and associated costs, contributing to a more sustainable and cost-effective operation.
  • Remote Monitoring and Control: Allows for monitoring and managing water usage from anywhere, providing greater flexibility and operational control.

Use Cases

Wireless water usage monitoring systems are applicable to various quarry operations, including:

  • Equipment Washing: Monitoring water usage for equipment washing stations to promote efficient water use and prevent waste.
  • Dust Suppression: Monitoring water usage for dust control systems to ensure optimal performance and minimize water waste.
  • Material Processing: Tracking water consumption in crushing, screening, and washing processes to identify areas for optimization.

Grain silo temperature measurement

Storing grain in silos presents challenges in maintaining quality and preventing spoilage. One critical factor is temperature, as rising temperatures within the grain mass can indicate the onset of fermentation, insect infestation, or mold growth. These conditions can lead to significant losses in grain quality and value. Traditional methods of temperature monitoring in grain silos often involve manual temperature checks using long probes or wired sensors, which can be labor-intensive, time-consuming, and provide limited visibility into temperature distribution within the silo. Wireless sensor systems offer a more efficient and comprehensive solution for monitoring grain silo temperatures.

Wireless Grain Silo Temperature Monitoring System

  • Long-Range Temperature Probes: Wireless temperature sensors with long probes are strategically inserted into the grain silo at various depths and locations. These probes are designed to withstand the dusty and potentially harsh environment inside the silo.
  • Wireless Data Transmission: The temperature data from the sensors is transmitted wirelessly to a central monitoring station, a computer, or a mobile device, providing real-time access to temperature readings throughout the silo.
  • Real-time Monitoring and Alerts: The monitoring system displays the temperature readings in real-time, allowing operators to continuously monitor conditions within the silo. The system can also be configured to trigger alerts if temperatures exceed pre-set thresholds, indicating potential problems such as fermentation or insect activity. This enables prompt intervention to prevent spoilage and maintain grain quality.

Benefits

  • Early Problem Detection: Continuous temperature monitoring allows for early detection of rising temperatures, enabling timely intervention to prevent spoilage.
  • Improved Grain Quality: Maintaining optimal temperature conditions helps preserve grain quality and minimize losses.
  • Increased Efficiency: Wireless monitoring eliminates the need for manual temperature checks, saving time and labor costs.
  • Data Logging and Analysis: The system can log temperature data over time, providing valuable insights for analyzing storage conditions and optimizing grain management practices.
  • Remote Monitoring: Allows operators to monitor silo temperatures from anywhere, providing greater flexibility and control.

Use Cases

This application is suitable for various types of grain silos, including those used for storing wheat, corn, soybeans, and other grains. Wireless temperature monitoring is particularly beneficial for large grain storage facilities where manual monitoring of numerous silos would be impractical.

Optimizing concrete production with wireless cement mixer monitoring

In the construction industry, ensuring the accurate and efficient loading of cement mixers is crucial for maintaining productivity and minimizing waste. Traditionally, monitoring the amount of concrete in a mixer truck has relied on visual estimation or mechanical methods, which can be inaccurate and inefficient. Wireless sensor systems offer a more precise and convenient solution for monitoring cement mixer loads, particularly in central filling stations where multiple trucks are loaded consecutively.

Wireless Cement Mixer Weight Monitoring System

  • Wireless Pressure Sensors: Wireless pressure sensors are strategically mounted on the hydraulic drive circuit of the cement mixer. The hydraulic pressure in the system is directly proportional to the force required to rotate the mixer drum, which in turn indicates the weight of the concrete load.
  • Wireless Data Transmission: The pressure data from the sensors is transmitted wirelessly to a receiver unit located at the central filling station.
  • Real-time Weight Monitoring: The receiver unit converts the pressure readings into weight measurements using pre-calibrated algorithms. This information is displayed in real-time, allowing operators to monitor the concrete load in each mixer truck accurately.

Benefits

  • Improved Accuracy: Provides precise weight measurements, ensuring accurate loading of cement mixers and minimizing waste.
  • Increased Efficiency: Streamlines the loading process, reducing the time required to fill each truck and optimizing overall productivity.
  • Reduced Costs: Prevents overfilling or underfilling of trucks, minimizing material waste and transportation costs.
  • Data Logging and Analysis: The system can log weight data for each truck, providing valuable insights for tracking concrete usage, optimizing production, and improving inventory management.
  • Wireless Convenience: Eliminates the need for cumbersome wiring or manual measurements, improving safety and efficiency at the filling station.

Use Cases

This application is particularly beneficial in central concrete mixing plants or filling stations where multiple trucks are loaded consecutively. It helps ensure that each truck receives the correct amount of concrete, optimizing production and minimizing material waste.

Looking Ahead

As the construction industry increasingly adopts technology to improve efficiency and sustainability, wireless sensor systems for cement mixer weight monitoring are expected to become even more prevalent. This technology offers a valuable tool for optimizing concrete production, reducing waste, and improving overall productivity in the construction sector.

Water reservoir signal transfer

Water reservoirs often require monitoring and control systems to manage water levels, regulate flow, and ensure operational efficiency. Traditionally, these systems have relied on wired communication networks to transmit signals from sensors and actuators to a central control station. However, installing and maintaining wired infrastructure across vast water bodies can be challenging, expensive, and potentially disruptive to the environment. Wireless sensor networks offer a more practical and cost-effective solution for signal transfer across water reservoirs.

Wireless Reservoir Signal Transfer System

  • Wireless Transmitters and Receivers: Wireless transmitters are installed at various points around the reservoir, such as water level sensors, flow meters, and control valves. These transmitters send signals wirelessly to a central receiver located at the control station.
  • Long-Range Wireless Communication: To cover the distances involved in reservoir applications, long-range wireless communication technologies are employed. These may include technologies like LoRaWAN, cellular communication, or even satellite communication for very remote locations.
  • Reliable Data Transmission: The wireless system is designed to ensure reliable data transmission even in challenging environments, with features such as error correction, signal redundancy, and robust antenna systems to overcome obstacles and interference.
  • Real-time Monitoring and Control: The control station receives real-time data from the wireless sensors, providing operators with up-to-date information on water levels, flow rates, and other critical parameters. This allows for remote monitoring and control of the reservoir’s operation, enabling efficient water management and prompt response to any abnormal conditions.

Benefits

  • Cost-Effectiveness: Eliminates the need for expensive and disruptive wired infrastructure, reducing installation and maintenance costs.
  • Flexibility and Scalability: Wireless systems are easily adaptable to changing needs and can be expanded or reconfigured without significant infrastructure modifications.
  • Reduced Environmental Impact: Minimizes the disturbance to the reservoir environment compared to trenching and laying cables.
  • Improved Reliability: Wireless technologies can offer robust and reliable communication even in challenging environments.
  • Remote Monitoring and Control: Enables efficient water management and prompt response to operational needs from a central location.

Use Cases

Wireless signal transfer systems are applicable to various reservoir applications, including:

  • Water Level Monitoring: Continuously monitoring water levels to optimize reservoir operation and prevent overfilling or depletion.
  • Flow Control: Regulating water flow through gates and valves to manage water distribution and maintain desired levels.
  • Leak Detection: Detecting leaks in pipelines or reservoir structures through pressure or flow monitoring.
  • Water Quality Monitoring: Transmitting data from water quality sensors to assess parameters such as pH, turbidity, and dissolved oxygen.

pH signal transfer for precise dosing control

Maintaining accurate pH levels is critical in various industrial processes, such as water treatment, chemical processing, and food production. Traditional pH monitoring and control systems often involve wired sensors connected to a central dosing control system. However, in some applications, installing and maintaining wired infrastructure can be challenging or impractical, especially in remote locations. Wireless sensor systems offer a more convenient and flexible solution for pH signal transfer, enabling precise dosing control and improved process efficiency.

Wireless pH Monitoring and Control System

  • Wireless pH Transmitters: Wireless pH transmitters are integrated with pH sensors, allowing for direct measurement of pH levels in the process. These transmitters are designed to withstand the specific environmental conditions of the application, such as corrosive chemicals or high temperatures.
  • Wireless Data Transmission: The pH data from the transmitters is sent wirelessly to a central dosing control system. The wireless communication technology used will depend on the range and environmental factors, with options including Bluetooth, Wi-Fi, cellular, or even satellite communication for remote locations.
  • Real-time Monitoring and Control: The dosing control system receives real-time pH readings from the wireless transmitters, providing operators with continuous visibility into the process. This allows for precise control of dosing pumps or other actuators to maintain the desired pH level.

Benefits

  • Improved Process Control: Real-time pH monitoring and wireless communication enable precise dosing control, optimizing process efficiency and product quality.
  • Increased Flexibility: Wireless systems eliminate the constraints of wired infrastructure, allowing for greater flexibility in sensor placement and system configuration.
  • Reduced Installation Costs: Eliminates the need for expensive wiring and trenching, reducing installation costs and complexity.
  • Remote Monitoring and Control: Enables remote monitoring of pH levels and control of dosing systems from a central location, improving operational efficiency.

Use Cases

Wireless pH signal transfer systems are applicable to various industries and applications, including:

  • Water Treatment: Monitoring and controlling pH levels in water treatment plants to ensure optimal water quality.
  • Chemical Processing: Maintaining precise pH levels in chemical reactions to optimize product yield and quality.
  • Food Production: Monitoring pH levels in food processing to ensure food safety and quality.
  • Pharmaceutical Manufacturing: Controlling pH levels in pharmaceutical production to maintain drug efficacy and stability.

Optimising level management of multiple boreholes

Managing water resources from multiple boreholes can be a complex task, especially when trying to balance water extraction with aquifer sustainability. Knowing the water level in each borehole is crucial for making informed decisions about which boreholes to pump from and at what rates. Traditional methods of monitoring borehole levels often involve manual measurements or wired sensors connected to a central control system. However, these methods can be time-consuming, labor-intensive, and limited in terms of real-time data access and automation capabilities. Wireless sensor systems offer a more efficient and sophisticated solution for managing water levels in multiple boreholes.

Wireless Borehole Level Monitoring System

  • Wireless Level Sensors: Wireless pressure sensors, specifically designed for submersible applications, are installed in each borehole to measure the water level. These sensors are typically housed in rugged enclosures to withstand the harsh conditions of the borehole environment.
  • Wireless Data Transmission: The water level data from the sensors is transmitted wirelessly to a central control station or a cloud-based platform. The wireless communication technology used will depend on the distance between the boreholes and the control station, with options including radio frequency, cellular, or even satellite communication for remote locations.
  • Real-time Monitoring and Analysis: The monitoring system provides real-time visibility into water levels in all monitored boreholes, allowing operators to continuously assess the availability of water resources. Data visualization tools can be used to display water level trends, compare levels across different boreholes, and generate reports for analysis and decision-making.
  • Intelligent Pump Control: The wireless level data can be integrated with a central control system that automatically manages the operation of pumps in each borehole. Based on pre-set rules and real-time water level information, the system can optimize pump operation to ensure efficient water extraction while preventing over-pumping and potential damage to the aquifer.

Benefits

  • Sustainable Water Management: Promotes responsible water use by providing accurate data on water levels and enabling intelligent pump control to prevent over-extraction.
  • Improved Efficiency: Real-time data and automated pump control optimize water extraction, minimizing energy consumption and operational costs.
  • Reduced Labor Costs: Eliminates the need for manual water level measurements and allows for remote monitoring and control, reducing labor requirements.
  • Enhanced Aquifer Protection: Prevents over-pumping and potential damage to the aquifer by intelligently managing water extraction based on real-time water level data.
  • Data-Driven Decision Making: Provides valuable data for analyzing water resource availability, optimizing pumping strategies, and ensuring long-term sustainability.

Use Cases

Wireless borehole level monitoring systems are applicable to various water management scenarios, including:

  • Municipal Water Supply: Managing water extraction from multiple boreholes to meet municipal water demands.
  • Irrigation Systems: Optimizing water usage for agricultural irrigation by intelligently controlling borehole pumps based on water availability.
  • Industrial Water Supply: Ensuring a reliable water supply for industrial processes by managing water extraction from multiple boreholes.
  • Environmental Monitoring: Monitoring groundwater levels in boreholes for environmental monitoring and research purposes.

Preventing production line downtime with wireless overhead trolley wear monitoring

In industrial settings, such as automotive assembly plants, overhead trolley systems are commonly used to transport materials and components along production lines. These systems typically consist of motorized trolleys that move along a track, carrying heavy loads. Over time, the trolley blocks, which connect the trolley to the track, can experience wear and tear, leading to a reduction in the force they can exert on the drive system. If this force falls below a critical level, the trolley’s drive mechanism can start to slip, potentially causing the entire production line to stop. Traditional methods of monitoring trolley block wear often involve manual inspections or wired sensors, which can be time-consuming, disruptive, and may not provide real-time alerts. Wireless sensor systems offer a more efficient and proactive solution for monitoring overhead trolley wear and preventing costly production line downtime.

Wireless Overhead Trolley Wear Monitoring System

  • Wireless Load Cells: Wireless load cells are embedded into the trolley blocks to measure the force they exert on the drive system. These load cells are designed to withstand the harsh conditions of an industrial environment and provide accurate force measurements.
  • Wireless Data Transmission: The force data from the load cells is transmitted wirelessly to a central monitoring station or a mobile device, providing real-time visibility into the condition of the trolley blocks.
  • Real-time Monitoring and Alerts: The monitoring system displays the force measurements in real-time, allowing maintenance personnel to track the wear and tear on the trolley blocks. The system can also be configured to trigger alerts if the force falls below a pre-set threshold, indicating potential slippage and the need for maintenance.

Benefits

  • Preventative Maintenance: Enables proactive maintenance by identifying trolley block wear before it leads to production line downtime.
  • Reduced Downtime: Minimizes costly production losses by providing early warning of potential slippage issues.
  • Improved Safety: Helps prevent accidents and equipment damage caused by trolley slippage.
  • Increased Efficiency: Allows for continuous monitoring of trolley block condition, optimizing maintenance schedules and improving overall efficiency.
  • Wireless Convenience: Eliminates the need for cumbersome wiring, minimizing disruption to the production environment.

Use Cases

This application is particularly valuable in industries with continuous production lines, such as automotive manufacturing, where even brief downtime can have significant financial implications. Wireless trolley wear monitoring helps ensure the smooth and efficient operation of these critical systems.

Streamlining vehicle production with wireless tailgate opening systems

In automotive manufacturing, efficient and ergonomic processes are essential for maximizing productivity and ensuring worker safety. During assembly line operations, workers often need access to the rear of the vehicle to perform various tasks, such as installing components, conducting inspections, or loading materials. Traditionally, opening the tailgate has required the worker to manually operate the tailgate latch or handle, which can be time-consuming, physically demanding, and potentially lead to repetitive strain injuries. Wireless tailgate opening systems offer a more efficient and ergonomic solution, automating the process and improving worker comfort and safety.

Wireless Tailgate Opening System

  • Wireless Transmitter: A wireless transmitter, typically integrated into a wristband or a handheld device, is worn by the worker.
  • Wireless Receiver: A wireless receiver is installed in the vehicle, connected to the tailgate latching mechanism.
  • Automatic Tailgate Opening: When the worker approaches the rear of the vehicle and activates the transmitter, the wireless signal triggers the receiver, which in turn activates the tailgate latch, automatically opening the tailgate.

Benefits

  • Improved Ergonomics: Eliminates the need for repetitive manual operation of the tailgate, reducing the risk of worker fatigue and strain injuries.
  • Increased Efficiency: Streamlines the assembly process, allowing workers to access the rear of the vehicle quickly and easily, improving overall productivity.
  • Enhanced Safety: Reduces the risk of accidents and injuries associated with manually operating heavy tailgates.
  • Wireless Convenience: Eliminates the need for wires or cables, improving worker mobility and flexibility on the production line.
  • Integration with Automation Systems: Can be integrated with other automation systems on the production line, further optimizing workflow and efficiency.

Use Cases

This application is particularly beneficial in automotive assembly plants where workers frequently need access to the rear of the vehicle. It can also be applied to other manufacturing or logistics environments where automated door or gate opening is desired.

Grain silo level measurement

Accurately measuring the level of grain or other materials stored in silos is crucial for inventory management, process control, and efficient operations. However, traditional level measurement methods can be cumbersome, unreliable, and difficult to implement in environments with multiple silos located close together. The abundance of metal structures in these environments can interfere with wireless signals, making traditional wireless level measurement challenging. A clever solution to overcome these challenges involves a combination of wired sensors and a strategically positioned wireless network.

Wireless Grain Silo Level Measurement System

  • Bottom-Mounted Level Sensors: Several suitable level sensor options can be mounted at the bottom of each silo to directly measure the level of material:
    • Capacitance probes: These probes measure the change in capacitance as the level of grain rises or falls within the silo. They are well-suited for this application as they are robust, relatively low cost, and can withstand the dusty environment inside the silo.
    • Load cells: Load cells can be installed under the silo’s support structure to measure the total weight of the grain. By knowing the silo’s dimensions and the density of the grain, the level can be calculated from the weight measurement.
  • Top-Mounted Sensors:
    • Weight and cable-based sensors: These sensors use a weight suspended by a cable to measure the distance to the grain surface. As the level changes, the cable extends or retracts, and the sensor measures the corresponding change in weight. These sensors are known for their reliability and accuracy in grain silo applications. However, they are typically suspended from the top of the silo, not bottom-mounted.
  • Elevated Antenna Network: The sensors are wired to antennas located at the top of the silo. These antennas are connected to a wireless network that effectively creates a communication “cloud” above the silos. This elevated network overcomes the signal interference caused by the metal silo structures.
  • Wireless Data Transmission: The level data from the sensors is transmitted wirelessly from the antennas to a central monitoring station or control system.
  • Real-time Level Monitoring: The monitoring system provides real-time visibility into the level of material in each silo, allowing operators to track inventory, optimize filling and emptying operations, and prevent overfilling or underfilling.

Benefits

  • Improved Accuracy: Direct level measurement using bottom-mounted sensors or accurate weight-based measurements provides reliable level data.
  • Overcomes Signal Interference: The elevated antenna network minimizes signal interference caused by metal structures, ensuring reliable wireless communication.
  • Scalability: The system can be easily scaled to accommodate a large number of silos in a small area.
  • Reduced Installation Costs: Compared to traditional wired systems, this solution can reduce installation costs by minimizing the amount of wiring required.
  • Remote Monitoring: Allows for remote monitoring of silo levels from a central location, improving operational efficiency.

Use Cases

This application is particularly beneficial in facilities with a high density of silos, such as grain terminals, feed mills, and cement plants. It provides an effective solution for overcoming wireless signal challenges and achieving accurate level measurement in these environments.

Product Help

Measurement types

What types of measurement can be converted to wireless using this wireless sensor system?

The IW series provides solutions for converting a wide range of analogue and digital signals to wireless. This includes signals from temperature, pressure, flow, inclination, humidity, force, and position sensors. It also handles signals from standard 4-20mA transmitters and AC current transformers.

Wireless receivers purpose and output choices

What is the purpose of the IWR series of receivers, and what types of outputs do they provide?

The IWR series of receivers are designed to receive data from the IWT wireless sensors. They are available with analogue outputs (4-20mA or 1-5Vdc), relay alarm outputs, and communication ports. The IWR-USB is ideal for datalogging to a PC, while the IWR-Port offers RS232, RS485, or Ethernet communication and Modbus register access.

Cloud based wireless sensor management

What capabilities does the IoT Gateway wireless receiver offer for industrial IoT deployments?

The IoT Gateway acts as a central hub for connecting various sensors and devices to the cloud. It features a wide range of inputs, including support for up to 128 IWT wireless sensors, analogue and digital I/O, RS232/485, Ethernet, I2C, and SPI interfaces. It supports secure MQTT messaging to cloud servers, has relay control/alarm outputs, and can be powered by battery or 12/24Vdc. It can also be fitted with an optional GPS and display. The gateway logs data and periodically uploads it to cloud-based servers.

Setup and monitoring software provided

What software tools are available for configuring and monitoring the wireless sensor network?

The following software tools are provided for configuring and monitoring their wireless sensor network. The IWU Config tool is used for configuring transmitters. The IWR-SET PC software is used for configuring wireless receivers. The IWR-USB receiver comes with packaged software for displaying all parameters and logging data to an Excel-compatible CSV file. IWR-Port also has Engineering, Chart, and Logging Set-up Displays.

Battery-powered wireless RTD monitoring with Modbus integration

I need a battery-powered solution to monitor four RTD temperature sensors. It must transmit readings wirelessly up to 200 meters and integrate with an existing Modbus TCP/RTU gateway. What equipment would you suggest for this task?

We would suggest the 4 x IWTT-Node-PT wireless temperature transmitter and a IWR-PORT wireless receiver for this application. The IWTT-Node-PT supports PT100 probe inputs, and is designed for long term operation on battery power up to 5 years at 10 second transmission interval update rate. The wireless system is designed to covers distances exceeding 200 metres, and the IWR-PORT can be specified with a Modbus TCP/IP (Ethernet) or Modbus RTU (RS485) output ensuring compatibility with your existing system.

Wireless sensor protocol

What type of protocol does this wireless sensor system use?

All the IW series wireless transmitters and receivers use the Long Range IEEE 802.15.4. 2.4GHz standard protocol.

Wireless sensor types

What are some examples of the “IWT” series of wireless sensors offered with this wireless system, and what do they measure?

The IWT series encompasses a variety of wireless sensors tailored for specific measurements. Examples include:

  • IWPT: Pressure Sensor
  • IWTT: Temperature Sensor
  • IWDigT: Switch Input Sensor
  • IWmAT: mA Input Sensor
  • IWVT: Voltage Input Sensor
  • IWCTT: Current Transformer sensor
  • IWTRhT: Temperature & Relative Humidity Sensor
  • IWTxT: mA Input with Transmitter Supply
  • IWLoadT: Load Cell Input
  • IWTiltT: Biaxial Inclinometer
  • IWPulsT: Pulse Input (Flow meter etc)

Using more than one receiver with the same transmitter

Can more than one type of receiver be setup to read from the same wireless transmitter without causing any conflict, or is it that not recommended?

Yes more than one receiver can be used to receive signals from the same transmitter.

It’s not quite as robust as a single receiver in that if one receiver acknowledges the signal but that signal hasn’t got to the other, the transmitter won’t try again until the next update period (typically 10s).

Related Documents

Wireless Sensor Transmitters Data Sheets

Wireless Receivers Data Sheets


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