Wireless Temperature Sensor, Vibration and Movement

SmartBUG®

Temperature Detection

Vibration Analysis

Gyroscope

Long Life

Asset Health Alerts

SmartBug® Wireless Temperature Sensor and Wireless Vibration Sensor

Key Features of SmartBug® Wireless Sensors

Smartbug® Wireless Vibration Sensor
SmartBug® with wireless transmitter
SmartBug® smartbuttons for temperature and vibration sensor management

Triaxial Accelerometer

The SmartBug® is equipped with a triaxial accelerometer, which means it can measure acceleration in three perpendicular directions. This capability is crucial for monitoring the movement and vibrations of industrial assets such as machinery, vehicles, or infrastructure. It provides a comprehensive view of how these assets are performing in real-time. ± 16 g or ± 200 g triaxial acceleration measurements, at up to 6,400 Hz per channel.

Triaxial Gyroscope

The triaxial gyroscope feature provides precise measurements of rotational movements in three dimensions, enabling comprehensive motion analysis and enhancing the product's versatility.

Miniature Size

One of the standout features of the SmartBug® is its compact size. Measuring only 27mm in diameter and 18mm in height, it can be easily installed in various applications without taking up much space. This versatility allows it to fit into tight spaces where larger wireless temperature sensors might not be practical.

Robust, Rail-Approved Design

The SmartBug® is designed to operate in demanding environments with high levels of vibration. Its robust wireless vibration sensor construction ensures it can withstand the rigors of industrial use. Additionally, it has received rail approval, making it suitable for deployment in the railway industry where vibrations are common.

Wireless Connectivity for Simplicity

SmartBugs® eliminate the need for cumbersome wires and cables. They communicate wirelessly over short-range radio (up to 50 m), simplifying installation and reducing the clutter associated with traditional wired sensor systems.

Simple Installation

Installing SmartBugs® is a straightforward process. They can be securely bonded to the target surface using structural adhesive. This simplicity means that the sensors can be up and running in a matter of minutes, minimising downtime during installation.

Long Battery Life

The SmartBug® is designed for long-term use. Its internal battery can typically last up to three years, reducing the need for frequent battery replacements. Furthermore, the intelligent sleep capacity helps conserve battery life, ensuring extended operational longevity.

Zero Maintenance

Once installed, SmartBugs® require minimal maintenance. Their robust design, long-lasting battery, and wireless communication reduce the need for regular upkeep. This "set it and forget it" approach to monitoring simplifies ongoing management and keeps maintenance costs low.

How the SmartBug® Data Flow works

How Smartbug® Works - from sensors to data capture and transmission

How SmartBug® wireless sensors are utilised in optimising industry.

SmartBug® application for port equipment

Ports

The SmartBug® is strategically placed on cranes, container handling equipment, and dock structures in ports to monitor vibrations, strains, and temperature. This data ensures the structural integrity of critical infrastructure and helps optimize equipment maintenance schedules, reducing downtime and enhancing the efficiency of port operations.

SmartBug® application in rail to monitor vibrations, strain and temperature

Rail

In the rail industry, SmartBugs® is attached to locomotives, freight cars, and tracks to track vibrations, strains, and temperature variations. This real-time data aids in predictive maintenance, allowing rail operators to identify potential issues before they become critical. It also helps improve the safety and reliability of rail transportation systems.

SmartBug® application for wind and power generation

Power Generation

In wind power generation, SmartBugs® are affixed to wind turbine components to monitor strain, vibration, and temperature, enabling proactive maintenance and maximising energy production efficiency.

Periodic Sampling

Adjustable to desired sensitivity and levels

User Adjustable

Sampling Frequency, Duration & Wake Interval

Edge Processing

Real-time data analysis & decision-making at the source.

Remotely Configurable Settings​

Multiple Smartbug® sensors presentation box

API Access

Real-time access via simple API (Application Programming Interface)

TRIGGERS

Adjustable RMS and peak-to-peak triggers

Benefits of using SmartBug®

Smartbug® Wireless Vibration Sensor
Smartbug® Smartbuttons Temperature Sensor

Increase Maintenance Efficiency

By adopting our solution, you can significantly enhance maintenance operations, streamlining processes and maximising resource utilisation for improved overall efficiency.

Wireless, Sensor-Based Solution

Our innovation leverages wireless temperature sensor technology and advanced wireless vibration sensors to offer a cutting-edge solution. It enables real-time monitoring and analysis of gearbox health, providing you with crucial insights into performance and potential issues.

Extend Maintenance Intervals

With our technology, you can extend maintenance intervals without compromising on operational safety. Continuous monitoring allows for predictive maintenance, reducing unnecessary downtime and costs associated with premature overhauls.

Rail Standards Compliant

The SmartBug® technology is full rail compliant. Our products are fully tested and are both EMC Tested and IP 68 rated.

Bearing Issues

SmartBugs® can detect early signs of bearing issues by monitoring vibrations and temperature variations. Sudden increases in vibration levels or temperature can indicate potential bearing failures, allowing for timely maintenance to prevent costly downtime.

Wear of gearbox components such as gears and bearings can cause an increase in noise and vibration, and lead to premature failure of the drive-train.

Our SmartBug/SOP technology identifies early gearbox issues; the pictured example exceeded fleet average vibrations, prompting client inspection and repair.

SmartBug/SOP technology

Out Of Balance

SmartBugs® can detect out-of-balance conditions by analyzing vibration data. Any deviations from the normal vibration signature can indicate imbalance issues, allowing for adjustments to be made to prevent further damage or wear.

Duty Cycle

SmartBugs® provide insights into the duty cycle of equipment by monitoring strain, vibration, and temperature changes during operation. This data helps in optimising maintenance schedules and ensuring that equipment is used within its designed duty cycle, increasing its lifespan.

Wheel flats are localised flat spots on train wheels caused by prolonged skidding, leading to increased vibration, noise, and track damage.

Our SmartBug/SOP technology automatically detects wheel flats, providing early alerts and trends; after detecting a 55mm flat, stakeholders were alerted, leading to the prompt turning of the wheel set.

Wheel flats

Wheel pits are depressions or cavities on the wheel surface.

Stress Concentration: Wheel pits can act as stress concentrators, leading to a heightened risk of crack initiation and propagation.

Premature Wheel Wear: Pits can accelerate the wear of the wheel, reducing its lifespan and leading to increased maintenance and replacement costs.

Track Damage: Pits can lead to uneven wheel-rail contact, which might result in localised rail damage or wear over time.

Reduced Ride Comfort: Wheel pits can cause inconsistent wheel-rail interactions, leading to vibrations that affect passenger comfort.

Increased Inspection Need: Wheel pits necessitate more frequent inspections to ensure the wheel’s condition is safe for continued operation.

Solution: Our SmartBug/SOP technology detects early-stage wheel pits, alerting clients in time for preventative tyre turning instead of relying on mileage-based maintenance.

Wheel pits

Rolling Contact Fatigue (RCF) is frequently a prevailing damage mechanism for wheel pans.

Our SmartBug/SOP technology detects RCF and ride quality issues early, providing alerts and trends. The graph demonstrates its effectiveness in alerting clients to RCF, allowing timely wheel set turning and extending wheel pan lifespan.

Rolling Contact Fatigue (RCF)

General Detection

Bearing Issues

SmartBugs® can detect early signs of bearing issues by monitoring vibrations and temperature variations. Sudden increases in vibration levels or temperature can indicate potential bearing failures, allowing for timely maintenance to prevent costly downtime.

Wear of gearbox components such as gears and bearings can cause an increase in noise and vibration, and lead to premature failure of the drive-train.

Our SmartBug/SOP technology identifies early gearbox issues; the pictured example exceeded fleet average vibrations, prompting client inspection and repair.

Wear of gearbox components

Out Of Balance

SmartBugs® can detect out-of-balance conditions by analyzing vibration data. Any deviations from the normal vibration signature can indicate imbalance issues, allowing for adjustments to be made to prevent further damage or wear.

Duty Cycle

SmartBugs® provide insights into the duty cycle of equipment by monitoring strain, vibration, and temperature changes during operation. This data helps in optimising maintenance schedules and ensuring that equipment is used within its designed duty cycle, increasing its lifespan.

Rail-Specific Detection

Wheel flats are localised flat spots on train wheels caused by prolonged skidding, leading to increased vibration, noise, and track damage.

Our SmartBug/SOP technology automatically detects wheel flats, providing early alerts and trends; after detecting a 55mm flat, stakeholders were alerted, leading to the prompt turning of the wheel set.

SmartBug/SOP technology

Wheel pits are depressions or cavities on the wheel surface.

Stress Concentration: Wheel pits can act as stress concentrators, leading to a heightened risk of crack initiation and propagation.

Premature Wheel Wear: Pits can accelerate the wear of the wheel, reducing its lifespan and leading to increased maintenance and replacement costs.

Track Damage: Pits can lead to uneven wheel-rail contact, which might result in localised rail damage or wear over time.

Reduced Ride Comfort: Wheel pits can cause inconsistent wheel-rail interactions, leading to vibrations that affect passenger comfort.

Increased Inspection Need: Wheel pits necessitate more frequent inspections to ensure the wheel’s condition is safe for continued operation.

Solution: Our SmartBug/SOP technology detects early-stage wheel pits, alerting clients in time for preventative tyre turning instead of relying on mileage-based maintenance.

Wheel pits

Rolling Contact Fatigue (RCF) is frequently a prevailing damage mechanism for wheel pans.

Our SmartBug/SOP technology detects RCF and ride quality issues early, providing alerts and trends. The graph demonstrates its effectiveness in alerting clients to RCF, allowing timely wheel set turning and extending wheel pan lifespan.

Rolling Contact Fatigue (RCF)

SmartBug® Customer Testimonials

SmartBug inspection image 1
SmartBug inspection image 2
"Just to inform you that we have now inspected inside the HP Cylinder housing of [the] compressor before its return to [service] (see attached photos). We [identified] some signs of scoring on both the inside of the housing and the piston. This appears to be a consequence of both operation and fitment (Horizontal and vertical markings)? The Teflon coating also appears to have degraded on the piston; beyond that I would expect from a newly overhauled compressor.”
Client Contribution
"Here's a picture taken and shared with [end client]. We will have the preliminary report by later today."

"Train has been pulled from service. It had an emergency brake which caused major flats. Good detection by the smart bugs as well."
alstom logo
Train System Expert
Alstom
Smartbug® Wheel pitting and flats issues
Smartbug® Wheel issue detection sensor system
"RCF tends to exacerbate without detection and by the time it does get booked the amount of material needed to be removed takes many thousands of miles off the wheelset life. Having [this] early detection could see a move to a more proactive intelligent preventative tyre turning rather than a mileage based event.”
angel trains
Fleet Improvement Manager
Angel Trains
"Looks like [SmartBug®] picked up its wheels on the trip yesterday morning, taken out of traffic immediately.

Set was examined last night and booked to go one journey only to [the depot] today to get the tyre turned.

On examination these flats were reported as 55 mm long, which is obviously out of traffic.”
northern
Fleet Improvement Manager
Northern Railway
Smart Oil Plug® Wheel Flats

SmartBug® Wireless Sensor Technical Specifications

Sensor
Triaxial Mems Accelerometer
Sampling Rate
6.4KHz/Channel
Dimensions [mm]
28mm x 15mm
Weight
19.2 g
Sleep mode current
5 µA
Operating Temperature
-40° to +85°C

Learn more about Smartbug® Wireless Sensors on LinkedIn.

Smartbug® Smartbuttons Temperature Sensor

How our SmartBug® wireless sensor system achieves results via Data Analysis

By combining numerous analytics techniques using both human-derived engineering analytics, combined with Artificial Intelligence, the SmartBug® Wireless Temperature Sensor and Wireless Vibration Sensor is able to give unparalleled diagnostics information.

1. Initial Data Organisation

Baseline Deviations

This enables rapid identification of irregularities, streamlining the troubleshooting process and minimising downtime.

Threshold Alerts

Employing an intricate alert system, we proactively identify deviations from established thresholds.

Spectral Analysis

This sophisticated technique uncovers nuanced patterns that can hold crucial information about system behaviour and anomalies.

Data Trending

This perspective offers invaluable insights into long-term behaviour patterns and potential trajectories.

Fleet Analysis

This comprehensive view empowers strategic decision-making by providing insights into fleet-wide performance, trends, and optimisation opportunities.

Usage Monitoring

This scrutiny allows us to identify wear and usage-related trends, facilitating predictive maintenance strategies.

2. Data Filtering

Human-Derived Engineering Analytics

Beyond the realm of automation, our process incorporates the expertise of human-derived engineering analytics. Our skilled professionals interpret the data in tandem with their industry know-how, adding a layer of contextual understanding that enhances the accuracy of our insights.

Multi-layer Perceptrons and Neural Networks

Utilising cutting-edge technology, we employ multi-layer perceptrons and neural networks. These advanced algorithms possess the capability to discern intricate patterns within the data, allowing us to uncover hidden correlations and anomalies that might go unnoticed through traditional methods.

  • Vibration Anomaly Detection
  • Rolling Contact Fatigue Detection
  • Wheel Flat Detection

3. Real-time Outputs

System Mobile SMS Alerts

Real-time Alerts

Get immediate SMS and email notifications to respond promptly to critical situations.

GDN® Data Analysis AI Portal

Asset Health Analysis

Explore in-depth asset health insights from advanced data analysis for informed decision-making.

Ease of Installation - Wireless Transmitter & Gateway

Transmitter Installation

CLEAN & GLUE

PRELOAD WITH MAGNETIC CLAMP

OPERATE SMARTBUG®

Gateway Installation

Insert SIM card

Supply Power

requires 24 V power

Remote system check

by our team at Transmission Dynamics

Smartbug® Wireless Vibration Sensor Transmitter Reciever

Part of the Transmission Dynamics Ecosystem

PANDAS-V®

This advanced system revolutionises rail industry practices by offering affordable and scalable remote condition monitoring solutions for electrified train pantographs and overhead lines.  By addressing maintenance challenges and enhancing efficiency, PANDAS-V transforms rail operations and sets new standards for monitoring and maintenance in the industry.

Smart Oil Plug®

The Smart Oil Plug® is an innovative technology designed for the railroad industry, providing real-time monitoring of final drives and transmissions via wireless data transmission, detecting various parameters like temperature, vibrations, oil debris, and more, while offering extended maintenance intervals and global data access.

PANDAS-3R®

PANDAS-3R® offers patented ultra-miniature wireless accelerometer technology for real-time data on train shoe gear impacts, boosting maintenance efficiency, ensuring safety, and embracing the future of rail maintenance.

Want to know more about the SmartBug® experience?

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