Under the wave of Industry 4.0, factory automation is moving toward a more intelligent and flexible direction. In factory automation applications, wireless sensing solutions can monitor equipment operating conditions, detect issues early, and facilitate predictive maintenance, reducing system downtime and helping to save operational costs while improving efficiency. This article will introduce the application of wireless sensing solutions in factory automation, as well as the related products and services provided by Murata.

Wireless sensing solutions offer predictive maintenance and condition monitoring
Currently, many wireless sensing solutions can be applied to factory and building monitoring systems, providing predictive maintenance and condition monitoring. Battery-powered wireless sensors enable remote monitoring of environments and equipment with minimal installation effort. The collected sensor data can be used for condition monitoring, predictive maintenance, productivity optimization, energy savings, and early detection of potential defects in both commercial and industrial fields.

Wireless sensing solutions help determine whether manufacturing machines are operating normally. These wireless sensor nodes are optimized for retrofitting, requiring almost no wiring, and can monitor the status of various machines/parameters in real time.

Wireless sensing solutions not only provide sensor data but also deliver actionable insights for predictive maintenance, energy savings, and productivity improvements in factories and buildings. For example, Murata's wireless sensing solutions enable the transition from time-based monitoring (TBM) to condition-based monitoring (CBM). By installing wireless sensors on existing equipment, you can monitor machine conditions, determine if maintenance is needed, and gain intuitive insights into operational rates. Sensor data can also help reduce unexpected downtime and stabilize production quality.

In manufacturing plants, manual monitoring of various gauges and meters is common. Wireless sensing solutions offer consistent analog data management, automating this time-consuming task and optimizing maintenance processes based on collected sensor data.

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Wireless sensors supporting time-based and condition-based maintenance
Traditional preventive maintenance involves regular maintenance of each machine to reduce the likelihood of potential defects. This method is also known as time-based maintenance (TBM). However, TBM can sometimes incur unnecessary costs, as parts may be replaced even when the machine is still functioning, or the machine may fail between maintenance intervals.

Condition-based maintenance (CBM) is another approach that uses sensor data to predict when a machine is likely to fail and when maintenance is required. CBM is more popular in manufacturing than TBM because it eliminates the need for periodic maintenance, significantly reducing maintenance costs.

For example, installing Murata's wireless sensor nodes on pumps with high failure rates allows you to predict their failure times and schedule maintenance as needed, saving unnecessary costs for parts and labor. These wireless sensors are easy to install, simply attach the nodes to the machines you want to monitor, and the system is ready. The system uses robust Sub-1GHz radio and repeaters, making it suitable for harsh environments like steel plants. Murata's wireless sensors and gateways are available for one-time purchase and include a free-of-charge Windows application for simple visualization and data logging, with no monthly fees or internet connection required.

Murata various wireless sensors can connect to the gateway and be used in a single system, allowing you to choose the appropriate sensors for your needs. Additional sensors can also be added to the existing system as necessary. Furthermore, you can use APIs to develop your own visualization or maintenance solutions.

In addition to providing complete wireless sensing solutions, Murata assists customers in evaluating and executing system installation processes. First, Murata works to understand the issues and challenges the customer aims to address with the wireless sensing system. Then, it offers suitable sensors and system configurations, provides quotes for evaluation kits, and supplies the kits for customers to assess sensor functionality and communication range before mass installation. Murata also assists with installation, expansion, and post-sales support.

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Wireless sensor solutions for vibration speed and temperature/humidity detection
Murata's factory monitoring system with wireless sensors includes a wide range of products, such as the vibration speed sensor units - LBAC0ZZ1TF and LBAC0ZZ1LZ. These sensors can be applied to rotating machinery like motors and pumps for predictive maintenance, improving equipment maintenance efficiency. The LBAC0ZZ1TF/LBAC0ZZ1LZ measures only 38 mm x 24 mm x 38 mm and weighs just 50 grams (including the battery). The communication interface uses a proprietary ISM sub-1GHz radio, certified for use in various regions/countries. It can measure peak acceleration (top two for LBAC0ZZ1TF, top five for LBAC0ZZ1LZ), frequency pf peak acceleration (top two for LBAC0ZZ1TF, top five for LBAC0ZZ1LZ), peak velocity (top three for LBAC0ZZ1TF), frequency pf peak velocity (top three for LBAC0ZZ1TF), acceleration RMS (LBAC0ZZ1TF/LBAC0ZZ1LZ), velocity RMS (LBAC0ZZ1TF), kurtosis (LBAC0ZZ1TF/LBAC0ZZ1LZ), and temperature (LBAC0ZZ1TF/LBAC0ZZ1LZ). The absolute maximum rating for measurements is ±30G, with a resolution of 28mG, and it supports an IP65 protection rating. The LBAC0ZZ1TF uses a lithium-thionyl chloride battery, offering a lifespan of up to 1.5 years (reporting interval: 1 hour, temperature: 25°C), while the LBAC0ZZ1LZ can last up to 5 years under the same conditions.

Murata also offers a vibration sensor - PKGM-200D-R, which can be used in consumer and industrial equipment for predictive maintenance through vibration monitoring. The drive circuit is built into a compact SMD package, allowing it to be embedded inside machines, making it ideal for installation on mechanical element components. It can detect high-frequency vibrations up to 11kHz, helping to identify vibration anomalies before abnormal noise or heat generation occurs, which aids in predictive maintenance for bearings and other components. The PKGM-200D-R can detect a wide frequency band in the Z-axis direction, with a minimum G-value detection range of ±10.2g and a typical sensitivity of 118mV/G. It features a built-in drive circuit, supports differential output for noise reduction, and includes a temperature sensor for operation in environments ranging from -20°C to 85°C. Murata also provides working samples for customer testing, with two types of test boards available: screw-fixed and adhesive tape type.

Another product is the temperature and humidity sensor unit - LBAC0ZZ1AN-345, which can be used for temperature monitoring in factories and buildings, contributing to energy savings, environmental compliance, and productivity improvements. The LBAC0ZZ1AN-345 measures 90 mm x 45 mm x 27 mm and weighs only 47.5 grams (excluding the battery). The communication interface supports a proprietary ISM sub-1GHz radio, certified for use in various regions/countries. It can measure temperature (-10°C to 60°C) and relative humidity (10%RH to 90%RH). The power source consists of two AAA lithium-ion batteries, offering a battery life of up to 10 years (reporting interval: 10 minutes, temperature: 25°C). It can also be powered by an AC adapter or USB cable.

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Comprehensive current sensing, repeater, and gateway solutions
Murata also offers CT current sensor units - LBAC0ZZ1MT-247/LBAC0ZZ1NT-248, which can be used to monitor equipment operating status, save energy, and improve production efficiency. The units measure 90 mm x 45 mm x 27 mm, with connection cable lengths of 150mm, 1500mm, or 3000mm, and weigh 50g (excluding the battery and cable). The communication interface supports a proprietary ISM sub-1GHz radio, with certified working frequencies for various regions/countries. They can measure current (AC 50/60Hz) in ranges of 0.1–80A, 0.1–200A, or 1–500A. The power source consists of two AAA lithium-ion batteries, offering a battery life of up to 9 years (reporting interval: 10 minutes, 25°C), or they can be powered by an AC adapter or USB cable.

Murata also provides a 4-20mA and pulse signal unit - LBAC0ZZ1MU-270, which wirelessly collects data from existing 4-20mA sensors, transitioning from manual and ad-hoc data logging to automated and consistent data collection, thereby improving production quality. The LBAC0ZZ1MU-270 measures 90 mm x 45 mm x 27 mm, with a connection cable up to 2m long, and weighs 50g (excluding the battery and cable). The communication interface supports a proprietary ISM sub-1GHz radio, with certified working frequencies for various regions/countries. It can measure 4-20mA and pulse signals (NPN, PNP), with a pulse count range of 0–65535 times. The power source consists of two AAA lithium-ion batteries, offering a battery life of up to 10 years (reporting interval: 10 minutes, temperature: 25°C), or it can be powered by an AC adapter or USB cable. Additionally, Murata offers another unit - LBAC0ZZ1RU-271, which supports 0-5V and pulse signals, with specifications similar to the LBAC0ZZ1MU-270.

Murata's repeater - LBAC0ZZ1AR-842, serves as a wireless communication range extender for large-scale installations. It measures 90mm x 45mm x 27mm and weighs 50g (excluding the battery). The communication interface supports a proprietary ISM sub-1GHz radio, certified for use in various regions/countries. The battery life is up to 9 years (reporting interval: 10 minutes, temperature: 25°C), or it can be powered by an AC adapter or USB cable.

Murata also provides a gateway - LBAC0ZZ1SU-848, measuring 170 mm x 109mm x 27mm (excluding the antenna and antenna connector) and weighing 250g (excluding the antenna). It features a sensor communication interface supporting a proprietary ISM sub-1GHz radio, with certified working frequencies for various regions/countries. The host communication interface supports WLAN (IEEE 802.11 b/g/n) and Ethernet (IEEE 802.3 10/100 Base-T). The power source is an AC adapter.

Conclusion
Wireless sensing solutions are becoming indispensable in the field of factory automation. With advantages such as flexible deployment, real-time data transmission, and low maintenance costs, these solutions enable enterprises to improve production efficiency, reduce operational risks, and accelerate the transition to smart manufacturing. As wireless communication technology continues to advance, these solutions will become even more stable and efficient, injecting more innovation into manufacturing and enabling higher levels of digital transformation and automated management. Murata offers a comprehensive range of wireless sensing solutions and services, helping customers accelerate their factory automation processes.