{"id":14384,"date":"2021-05-19T11:18:06","date_gmt":"2021-05-19T16:18:06","guid":{"rendered":"https:\/\/blog.wika.com\/us\/\/?p=14384"},"modified":"2026-01-30T13:23:14","modified_gmt":"2026-01-30T18:23:14","slug":"leap-sensors-by-phase-iv-engineering-a-breakthrough-in-wireless-sensor-systems","status":"publish","type":"post","link":"https:\/\/blog.wika.com\/us\/applications\/leap-sensors-by-phase-iv-engineering-a-breakthrough-in-wireless-sensor-systems\/","title":{"rendered":"Leap Sensors by WIKA IIoT Solutions, a Breakthrough in Wireless Sensor Systems"},"content":{"rendered":"

WIKA IIoT Solutions launches its next-generation Leap Sensors\u00ae<\/sup>, a powerful yet easy-to-install modular wireless system that allows users to incorporate industrial IoT and predictive maintenance throughout their facility.<\/strong><\/p>\n

Ever since the Industrial Revolution, manufacturers would schedule maintenance for their machinery or simply replace a part when it fails. This approach works, for the most part, but it can also be inefficient, time-consuming, and \u00ad\u2013 in the worst-case scenario \u2013 dangerous. Take a plant air compressor, for example: If a bearing fails, the entire plant can go down unexpectedly for hours.<\/p>\n

Now, imagine a set of sensors that allows operators to \u201csee\u201d into a process\u2019s conditions in real-time and gives ample warnings before a problem occurs. The entire system is wireless, compact, reliable, and can be fully configured and integrated into existing processes in about five minutes.<\/p>\n

Leap Sensors\u00ae<\/sup> System: Modular, Rugged, Future-Proof<\/h2>\n

The mission of WIKA IIoT Solutions<\/a>, a WIKA USA partner<\/a>, is to take companies to the next level of manufacturing: Industry 4.0. After 25 years of custom sensor design work, Phase IV has created the next generation of its Leap Sensors\u00ae<\/sup> wireless system for predictive maintenance<\/a> and the industrial Internet of Things (IIoT).<\/p>\n\n

\"Leap

Leap Sensors wireless motor monitoring system with amp clamp, thermocouple, and optional magnet mount<\/p><\/div>\n \n

The transceiver nodes enclose sensors that monitor various conditions: vibration, temperature, pressure, humidity, strain, load, electrical current, and more. Multiple sensors of different types can be combined on one transceiver node, making for a cost-effective, easily adaptable system. A powerful microprocessor uses edge computing to convert high-volume readings (such as vibration) into a few actionable indicators \u2013 all without burdening software or data repositories. Its long-range antenna resides entirely inside the enclosure for a streamlined profile, and the onboard, easily replaceable battery typically lasts five to 10 years.<\/p>\n

The entire transceiver node is encased in a polycarbonate IP68 enclosure<\/a> with a UL 94 V-0 flammability rating (non Ex-rated) and can withstand harsh conditions, including wash-downs. Customization options include attaching thermocouples<\/a> to the enclosure to monitor temperatures up to 1,200\u00b0C (2,192\u00b0F), or RTD sensors for monitoring temperatures down to \u221280\u00b0C (\u2212112\u00b0F). The entire device comes standard with screw-mount flanges; for even easier mounting, a magnet option is available.<\/p>\n

A gateway receives sensor data over the air from up to 250 transceiver nodes, and easily interfaces with the Leap software or existing software (such as SCADA) leveraging standard Modbus or the Leap internet protocol (IP) API. A cellular gateway option is available for remote locations. For extra security and peace of mind, data transmissions use advanced encryption (AES-128) from end to end.<\/p>\n

Because the system is entirely IP-based, any<\/em> computer, tablet, or smartphone can connect to the software using a web browser to set email and SMS alert thresholds, check graphs for trends, download date, or configure sensor transmit intervals.<\/p>\n

What\u2019s more, the Leap Sensors system is future-proof. As their monitoring needs change, customers can easily modify monitoring parameters and alerts, or add sensors to the system. Since transceiver nodes automatically connect and auto-configure the software, expanding the system and implementing updates is hassle-free.<\/p>\n

X-Ray Vision and Crystal Ball in One Device\u2122<\/h2>\n

The Leap Sensors wireless sensor system saves users money and headaches. A WIKA IIoT Solutions client recently installed a motor sensor system. Within the first two weeks of use, the system detected a motor that was about to fail. So, what could have been a $200,000 loss in terms of downtime, lost product, and replacement expenses was instead a scheduled repair that cost only $3,500 and two hours of labor during planned maintenance.<\/p>\n

The owner of a Pennsylvania-based system integration company also attests to the Leap Sensors\u2019 effectiveness. \u201cWe received an alert when a freezer wasn\u2019t functioning properly. We were able to quickly fix the problem and save our products. That more than paid for the cost of the system right there.\u201d<\/p>\n

Satisfied customers rave about the actionable data from their Leaps Sensors system. Another client said, \u201cIt\u2019s like X-ray vision and a crystal ball combined. Now we can see exactly what\u2019s happening in our key manufacturing processes \u2013 and know ahead of time when a problem might occur.\u201d<\/p>\n

Wireless Monitoring System with Built-in Flexibility<\/h2>\n

For a wide range of industrial and commercial applications, WIKA IIoT Solutions offers a choice of monitoring systems:<\/p>\n