Monitoring Pump & Motor Systems

Using Lansitec Bluetooth Sensor with Accelerometer and Lansitec LoRaWAN Gateway

Introduction

Purpose

This case study explores the importance of monitoring movement in industrial environments. Industrial applications on any scale rely on various motors for making machinery work and proactively monitoring those motors can prove crucial for manufacturing processes. The case study will explore the use of Lansitec's B005 Bluetooth Beacon with additional built-in accelerometers and the SocketSync Bluetooth Gateway with LoRaWAN for monitoring a pump and motor system. The sensors are deployed to measure vibrations and detect abnormalities in the system's operational behavior via a beaconing technology, transmitting real-time data to the cloud for monitoring and alerting.

Importance of Condition Monitoring

Keeping track of the state of motors is crucial to guarantee their effective and dependable performance. Industrial systems are susceptible to wear, misalignment, and other problems causing excessive vibrations, potentially leading to expensive downtime or equipment failure. Continuous monitoring helps detect problems early, leading to preventive maintenance and reducing unexpected breakdowns. Using IoT technology such as Lansitec sensors can help businesses improve equipment lifespan, cut down on maintenance expenses, and optimize operational effectiveness.

System Overview

Pump and Motor System

The typical motor-pump setup, that we are using to illustrate this use case, is used in industries like water distribution, HVAC, and manufacturing, and involves the motor converting electrical energy into rotational motion. The pump then transfers this mechanical energy to move liquids through piping systems. This seamless interaction is critical for continuous operations in various sectors. For example, in water distribution, pumps ensure consistent flow rates to meet demand, while HVAC systems rely on pumps to circulate fluids for heating and cooling.

Challenges

Motor-pump systems frequently face several operational challenges. Factors such as wear and tear, component misalignment, and rotor imbalances can cause excessive vibration over time, which is a crucial sign of system deterioration. Vibrations have the potential to harm bearings, seals, and couplings, resulting in mechanical strain and ultimately leading to early breakdowns. Common issues include:

Misalignment

Improper alignment of motor and pump shafts leads to added strain on bearings and seals.

Bearing Wear

Extended use without adequate lubrication or dirty lubricants speeds up wear and tear on bearings, decreasing efficiency.

Imbalance

Unequal weight distribution in rotating parts leads to increased vibrations, putting strain on mechanical components.

Sensor and Gateway Technology

Introducing Lansitec devices that significantly help to monitor pump's condition

B005 Bluetooth Beacon

The bluetooth beacon constantly advertises iBeacon messages according to settings. It has two built-in high-capacity button cells. The maximum battery life is approximately 5 years with a advertise interval @500ms.

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Lansitec B005 Bluetooth Beacon with Accelerometer

This Bluetooth beacon can be integrated with a high-precision accelerometer, capable of detecting subtle vibrations and rotational speeds, which is critical for monitoring motor and pump health.

Key features include:

Bluetooth 5.0

Provides low-energy, wireless communication, enabling real-time data transmission to nearby gateways within a range of 100 meters.

Accelerometer

Measures vibrations in three axes, detecting even minor deviations from normal operating conditions, such as increased vibrations due to misalignment or mechanical wear.

Compact Size & IP67 Rating

The beacon’s small form factor and robust housing allow it to be installed in harsh environments like pump houses, ensuring accurate data collection without the need for wired connections.

Benefits for the Use Case

The small size and ease of installation mean the sensor can be placed directly on critical components of the motor and pump, such as the rotor and pipe connection, where it can continuously monitor for excessive vibrations and alert users to issues before they lead to system failure. Its Bluetooth capability ensures that data is wirelessly transmitted to the gateway without complicated wiring, reducing installation time and maintenance complexity.

SocketSync Bluetooth Gateway

The SocketSync Bluetooth Gateway is designed based on BLE and LoRa technology. With the advanced LoRa technology and built-in BLE module, the BLE gateway receives and reports the BLE devices messages to the LoRaWAN gateway. The parameter settings, such as the heartbeat period, LoRaWAN work mode, and sensor data to send in a BLE message, are adjustable as per customers’ requirements.

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Lansitec SocketSync Bluetooth Gateway

The Socket Sync Gateway acts as the data bridge, collecting information from the Bluetooth sensors and forwarding it to the cloud for analysis.

Its specifications include:

Bluetooth 5.0

Enables the gateway to connect with numerous Bluetooth sensors at the same time up to a distance of 100 meters.

Wi-Fi and Ethernet Connectivity:

Offers various ways to connect for transferring data to the cloud, guaranteeing dependability across different network settings.

LoRaWAN Data Forwarding:

The gateway transmits data over extended distances through the LoRaWAN protocol, ideal for remote or large-scale setups.

Benefits for the Use Case

The gateway’s ability to handle multiple sensor connections makes it scalable for systems with several motor-pump setups. Its ability to connect to transmit via LoRaWAN and the Wi-Fi backhaul ensures that data is sent to the cloud smoothly, even in areas with no, unreliable cellular or wired internet access. This guarantees continuous monitoring and activation of alarms if abnormal sensor readings are detected.

Introduction to LoRaWAN Technology

What is LoRaWAN Communication Protocol?

LoRaWAN is a low-power, long-range wireless communication technology, one of the big advantages of large-scale deployments. It enables data transmission over several kilometers with minimal energy use. This is especially useful in industrial settings where systems are spread across large areas.

Key Features Include:

Long-Range Communication

Covers distances of up to 15 kilometers in rural areas and several kilometers in urban environments.

Low Power Consumption

Ideal for IoT deployments where devices are powered by batteries or solar energy, allowing sensors and gateways to operate for extended periods without requiring frequent maintenance.

Benefits for the Use Case

Through the use of LoRaWAN, the system can send important operational information from the pump house to the cloud, even when the location is distant. This feature allows for easy integration in large facilities or installations spread out over a wide area, minimizing the necessity for manual checks and guaranteeing consistent, dependable monitoring of the motor and pump system.

Implementation Process

Installation

The Bluetooth sensors are installed directly on the motor's rotor and on the pump at the pipe connection point, where vibrations are most likely to reveal operational issues. Their compact design and wireless functionality allow for easy mounting using adhesives or clamps without disrupting existing machinery. The Lansitec Socket Sync Gateway is mounted on the pump house roof, where it has a clear line of sight to the sensors, ensuring optimal Bluetooth connectivity and signal strength.

To ensure accurate readings, calibration of the accelerometer is crucial. The sensor must be calibrated to baseline vibration and rotational speed under normal operating conditions. This step allows the system to distinguish between acceptable operational vibrations and warning signs of potential mechanical issues. Calibration can be done via software, typically using the associated app or web platform.

Data Flow

After installation, the Lansitec Bluetooth Beacon with Accelerometer continuously captures data regarding vibrations, acceleration, and rotational speed from the motor and pump. The accelerometer detects even the slightest irregularities in the mechanical behavior of the system. Here’s a more detailed step-by-step breakdown of the data flow:

LoRaWAN

Tracker

NB-IoT & LTE-M

Tracker

LoRaWAN

Sensor

Monitoring Pump & Motor Systems

Introduction

Purpose

Importance of Condition Monitoring

System Overview

Pump and Motor System

Challenges

Misalignment

Bearing Wear

Imbalance

Sensor and Gateway Technology

B005 Bluetooth Beacon

Lansitec B005 Bluetooth Beacon with Accelerometer

Bluetooth 5.0

Accelerometer

Compact Size & IP67 Rating

Benefits for the Use Case

SocketSync Bluetooth Gateway

Lansitec SocketSync Bluetooth Gateway

Bluetooth 5.0

Wi-Fi and Ethernet Connectivity:

LoRaWAN Data Forwarding:

Benefits for the Use Case

Introduction to LoRaWAN Technology

Long-Range Communication

Low Power Consumption

Benefits for the Use Case

Implementation Process

Installation

Data Flow

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