Intuitive, Actionable Maintenance Advice
for Industrial Blowers and Pumps as OEM

Measures and Predicts:

  • Vacuum pressure level
  • Bearing condition
  • Valve condition
  • Filter condition
  • Belt tension condition
  • Oil viscosity
  • Oil level warnings
  • Blower/gear condition

 

 

MEASURES:

Vacuum

Vibration

Temperature

Pressure

Sound

Magnetic field

PREDICTS:

Vacuum level

Bearing condition

Valve condition

Filter condition

Belt tension level

Oil condition

Gearbox condition

Rotor/starter health

The PumpSense Sensor easily attaches to the outside of the blower housing and constantly measures vibration, temperature and vacuum/pressure.  An onboard power supply connects directly to the machine power eliminating the need for batteries.

The data stream is sent to cloud servers where proprietary analytic algorithms compare the data against typical baselines to determine overall pump/blower health, filter status, oil status, pump utilization and vacuum/pressure levels.

Machine analytics are then shown within an intuitive desktop and mobile app for at-a-glance user understanding of what’s going on with single or multiple blowers/pumps.  PumpSense will deliver actionable intelligence and predict potential component failures, significantly reducing the cost and inconvenience of unscheduled downtime.


1Sensor
2Data Hub
3Router
4Cloud-based Servers
5Desktop Predictive Analytics Software
6User-friendly App
7Actionable Maintenance Advice

*PumpSense Sensor Housing easily attaches to outside of blower housing.
*Included Power Supply eliminates the need for sensor batteries.
*Included Datahub constantly sends raw encrypted data to cloud servers for analysis.
*Proprietary algorithms constantly compare data for filter status, oil status, pump utilization, vacuum/pressure levels and overall blower/pump health.
*Included intuitive desktop and mobile app quickly and visually shows user what’s going on to avoid unplanned machine and component downtime.

PumpSense Vibration Sensor

Mechanical

Weight

7.0 oz (0.2 kg)

Dimensions
length x width x depth

2.6 in x 1.7 in x 1.1 in
(
66.7 mm x 42.7 mm x 27.6 mm)

Sensor housing material

Metal plastic hybrid

Enclosure rating

IP64, IP65 optional

Environmental

Operating temperature

Ambient temperature

14°F (-10°C) to 149°F (65°C)

Surface temperature

up to 185°F (85° C)

Hazardous condition

Class-1 Div-2

Acceleration

Range

– 16g to + 16g

Resolution

2%

Accuracy

10 mg

Sampling rate (configurable)

300/3000 per minute

Power

Power supply (built in)

3.3 volt DC adapter

Bluetooth Communication

Bluetooth Low Energy (BLE)Range

15 ft

Bluetooth Low Energy (BLE)Tx power

-5.8 dBm

Bluetooth Low Energy (BLE)Standard

4.1

PumpSense Vacuum Control

Mechanical

Weight

1.5 lb (0.7 kg)

Dimensions
length x width x depth

4.8 in x 5.3 in x 2.0 in
(121 mm x 135 mm x 50 mm)

Enclosure material

Powder-coated steel

Enclosure rating

IP64

Vacuum Sensor

Vacuum range (from atmospheric pressure)

0-15, 0-30 PSI; 0-30.54, 0-61.08 InHg; 0-77.5,155.14 cmHg

Resolution

0.01

Accuracy (full scale span)

0.35%

Update rate

1 per second

Vacuum inlet

1/8 inch OD polyurethane tube

Environmental

Operating temperature range

14°F (-10°C) to 149°F (65°C)

Power

Power in

24VDC or 110 – 270VAC

Power out

3.3 volt

Bluetooth Communication

Bluetooth Low Energy (BLE) Range

15 ft

Bluetooth Low Energy (BLE) Tx Power

-7.5 dBm

Bluetooth Low Energy (BLE) Standard

4.1

DATA HUB

Functional

Connect to machine sensor, pump sensor and
electro-sensor via Bluetooth Low Energy (BLE)

Two days of storage data for disconnected applications
(1 data set/second rate)

Maximum of 3 years if 1 data set/ 10 minute rate

Smart-phone/tablet-based WiFi connect app (WiFigurator)

Auto-upgrade over Internet

Mechanical

Mounting

Rail/wall mount

Enclosure rating

IP50

Dimensions
length x width x depth

4.8 in x 3.0 in x 1.3 in
(121 mm x 76 mm x 33 mm)

Weight

2.3 oz (0.06 kg)

Environmental

23°F (-5°C) to 150°F (65°C)

Power

5 volt DC adapter from
110 – 270VAC

ELECTRONICS

Processor

Quad core 1.2G Hz broadcom BCM2837 64-bit CPU

Memory

Micro SD card

Storage

16 GB

RAM

1 GB

I/O

40-pin extended GPIO and 4 USB Ports, full size HDMI, LAN

Radio

BCM43438 WiFi and Bluetooth Low Energy (BLE) on board

OS

Linux

Certification

CE/IEC/FCC

PumpSense™ Sensor

pumpsense-specs-topbottom-view

PumpSense™ Vacuum Control

pumpsense-specs-topside-view

Vacuum blowers and pumps are used in diverse industrial applications to move granules or other shapes.  Prophecy sensors have been field tested with many major blower manufacturer products and the list is always growing.  Applications for vacuum blowers and pumps include:

  • Plastics conveying (Novatec OEM product offering, see www.novatec.com)
  • Agricultural products
  • Food and beverages
  • Medical devices
  • Mining and construction
  • Packaging
  • Pharmaceutical
  • Textiles
  • Woodworking
  • Many other general industrial applications

Overview

Prophecy Sensorlytics' PumpSenseTM monitors current operating condition and trend health of pumps and blowers in various industrial applications. The PumpSense system provides easy- to-understand, actionable maintenance advice in advance of machine or component failure. The PumpSense sensor easily attaches to the pump housing and constantly measures vibration, temperature and either vacuum or pressure in the supply line. A plug-in connection reliably powers the sensor, unlike competitive units that rely on batteries for power. Prophecy’s proprietary analytics algorithm tracks and compares the collected data against a baseline to determine overall pump health. Filter status, oil status, pump utilization and vacuum or pressure level trends are all constantly monitored. Visualization of valuable operating metrics is delivered through easy-to-understand mobile and desktop dashboards. PumpSense will accurately predict and alarm in the event of looming machine and component failures, signi cantly reducing the cost and inconvenience of unscheduled equipment downtime. The PumpSense monitoring solution includes Prophecy’s comprehensive software, enabling the user to set up alarms and alarm recipients. Six months of historic data is available through equipment performance trend lines. And, a streamlined dashboard interface delivers a clear summary of the powerful analytics for all monitored equipment, neatly organized by department and location.

How it Works

1Sensor 2Data hub 3Router 4Cloud-based servers 5Desktop predictive analytics software 6User-friendly app 7Actionable maintenance advice
Prophecy sensors are placed directly on your machines or components to automatically monitor condition. The sensor data transmits to an easy-to-install gateway and is then sent to cloud-based servers running powerful analytic software. Results are transmitted from the server to a user-friendly app where you will view machine condition and maintenance advice.

Features & Benefits

  • Affordable, low investment and easy to install on existing equipment
  • 24/7/365 constant automatic monitoring, no complicated manual measurements
  • Dedicated power supply, no need to change sensor batteries
  • Easy-to-understand maintenance advice via text or email messages
  • Hand-held and desktop dashboards clearly present current status, trends and actionable maintenance advice, no overwhelming manual data analysis
  • Accurate prediction of machine and component failures, significantly reduced unscheduled machine downtime
  • Real time and historic vacuum or pressure performance data

Images

Dashboards

Specifications

PumpSense Sensor

Mechanical

Weight

7.0 oz (0.2 kg)

Dimensions length x width x depth

2.6 in x 1.7 in x 1.1 in (66.7 mm x 42.7 mm x 27.6 mm)

Sensor housing material

Metal plastic hybrid

Enclosure rating

IP64, IP65 optional

Environmental

Operating temperature

Ambient temperature

14°F (-10°C) to 149°F (65°C)

Surface temperature

up to 185°F (85° C)

Hazardous condition

Class-1 Div-2

Acceleration

Range

- 16g to + 16g

Resolution

2%

Accuracy

10 mg

Sampling rate (configurable)

300/3000 per minute

Power

Power supply (built in)

3.3 volt DC adapter

Bluetooth Communication

Bluetooth Low Energy (BLE)Range

15 ft

Bluetooth Low Energy (BLE)Tx power

-5.8 dBm

Bluetooth Low Energy (BLE)Standard

4.1

PumpSense Vacuum Control

Mechanical

Weight

1.5 lb (0.7 kg)

Dimensions length x width x depth

4.8 in x 5.3 in x 2.0 in (121 mm x 135 mm x 50 mm)

Enclosure material

Powder-coated steel

Enclosure rating

IP64

Vacuum Sensor

Vacuum range (from atmospheric pressure)

0-15, 0-30 PSI; 0-30.54, 0-61.08 InHg; 0-77.5,155.14 cmHg

Resolution

0.01

Accuracy (full scale span)

0.35%

Update rate

1 per second

Vacuum inlet

1/8 inch OD polyurethane tube

Environmental

Operating temperature range

14°F (-10°C) to 149°F (65°C)

Power

Power in

24VDC or 110 - 270VAC

Power out

3.3 volt

Bluetooth Communication

Bluetooth Low Energy (BLE) Range

15 ft

Bluetooth Low Energy (BLE) Tx Power

-7.5 dBm

Bluetooth Low Energy (BLE) Standard

4.1

DATA HUB

Functional

Connect to machine sensor, pump sensor and electro-sensor via Bluetooth Low Energy (BLE)

Two days of storage data for disconnected applications (1 data set/second rate)

Maximum of 3 years if 1 data set/ 10 minute rate

Smart-phone/tablet-based WiFi connect app (WiFigurator)

Auto-upgrade over Internet

Mechanical

Mounting

Rail/wall mount

Enclosure rating

IP50

Dimensions length x width x depth

4.8 in x 3.0 in x 1.3 in (121 mm x 76 mm x 33 mm)

Weight

2.3 oz (0.06 kg)

Environmental

23°F (-5°C) to 150°F (65°C)

Power

5 volt DC adapter from 110 - 270VAC

ELECTRONICS

Processor

Quad core 1.2G Hz broadcom BCM2837 64-bit CPU

Memory

Micro SD card

Storage

16 GB

RAM

1 GB

I/O

40-pin extended GPIO and 4 USB Ports, full size HDMI, LAN

Radio

BCM43438 WiFi and Bluetooth Low Energy (BLE) on board

OS

Linux

Certification

CE/IEC/FCC

PumpSenseTM Sensor

pumpsense-specs-topbottom-view

PumpSenseTM Vacuum Control

pumpsense-specs-topside-view

Applications

Vacuum blowers and pumps are used in diverse industrial applications to move granules or other shapes.  Prophecy sensors have been field tested with many major blower manufacturer products and the list is always growing.  Applications for vacuum blowers and pumps include:
  • Plastics conveying (Novatec OEM product offering, see www.novatec.com)
  • Agricultural products
  • Food and beverages
  • Medical devices
  • Mining and construction
  • Packaging
  • Pharmaceutical
  • Textiles
  • Woodworking
  • Many other general industrial applications