The system requires only the card tracker and mobile phones: the tracker samples 3-axis vibration and infers health states locally, broadcasting alerts over LoRa mesh to nearby phones without cellular base stations.
Industrial Vibration Anomaly Detection with T1000-E
Detect machinery vibration on-device and broadcast alerts to phones off-grid.
Out-of-the-box Meshtastic off-grid mesh communication on T1000-E, combined with edge vibration anomaly detection for industrial inspection alerts.
Reusable Site Templates
Rotating machinery, sites without cellular coverage, and alerts that must reach local staff immediately.
Industrial Pumps & Compressors
Chemical underground pump rooms, mineral wash stations, cooling water tunnels. The card mounts to the motor bearing housing to detect wear and vibration anomaly on-device.
Remote Conveyor Pulleys & Blowers
Quarry crushers, belt conveyor drives, and remote agricultural irrigation pumps. Uses multi-hop LoRa mesh to bridge kilometers without cabling or telecom towers.
Factory Assembly Lines & Gearmotors
Automotive assembly lines, automated warehouse roller conveyors, packaging machines. The card mounts to gearbox casings and drive sprockets to alert on gear wear and mechanical jams before unplanned downtime.
Not a fit: Long-term water immersion, ultra-high-frequency vibration (>1000Hz requiring piezoelectric probes), soft foam damping mounts.
How it works
The card tracker mounts directly on machinery, detects anomalies on-device, and relays alerts to nearby phones over LoRa mesh.
Tracker & Mounting
Powered by the SenseCAP Card Tracker T1000-E, featuring an onboard 3-axis accelerometer and LoRa/BLE radio:
- Rigid Surface Mounting: Mount onto motor or pump bearing housings using firm acrylic adhesive tape to ensure damping-free vibration conduction.
- Extended Battery Life: Built-in 700 mAh rechargeable battery with 30 μA deep sleep between periodic wakes, lasting 1 to 1.5 years on duty.
- Magnetic Fast Recharge: Top up battery via the magnetic USB cable whenever needed.
Edge Detection Engine
Inference runs locally on the Nordic nRF52840 MCU without streaming raw waveforms:
- Dynamic Gravity Decoupling: Automatically removes the static 1G gravity vector regardless of mounting orientation.
- 6D Feature Extraction: Extracts RMS velocity, Kurtosis, Peak, Crest Factor, and frequency energy distributions in 15 ms.
- SenseCraft AI Calibration: Connect via magnetic USB to the SenseCraft AI web studio; 10 seconds of steady rotation completes baseline training.
Off-Grid Mesh & Mobile
Combines Semtech LR1110 radio with open-source Meshtastic mesh protocol for completely off-grid communication:
- Multi-Hop Mesh Network: Relays packets across field nodes with 1 to 3 km range, free of SIM cards, routers, or towers.
- Mobile App Alerts: Staff receive instant popup notifications and acoustic alerts on the official Meshtastic mobile app via Bluetooth.
- Dual Network Modes: Easily flashable to LoRaWAN mode (Cayenne LPP payload) to feed legacy industrial gateways and SCADA platforms.
How well it works
What inspection staff see and operate on the web studio and mobile app.
Measured results
| Metric | Measured Value | Benchmark Conditions |
|---|---|---|
| Edge Feature Latency | < 15 ms | nRF52840 256-point 6D feature extraction and distance inference |
| Mesh Alert Delay | < 1.2 s | From anomaly detection trigger to first-hop LoRa packet broadcast |
| Deep Sleep Current | ~30 μA | Idle period between inspection wakes with hardware timer running |
| Inspection Battery Life | 1 to 1.5 years | 700 mAh internal battery, 10-minute wake interval, hourly heartbeat |
| Off-Grid Line-of-Sight | 1 to 3 km | Field LoRa multi-hop ad-hoc propagation without cellular base stations |
What you get out of it
| Output Channel | Payload & Format | Typical Integration |
|---|---|---|
| Meshtastic Broadcast | [WARN] Motor Anomaly! Score: xx, RMS: xx, Kurt: xx | Mobile app popups, handheld text alerts, and node map markers |
| USB Serial JSON Stream | {"type":2,"name":"AccelerometerData","x":..,"y":..,"z":..} | Streamed to SenseCraft AI Web Studio for calibration and tuning |
| LoRaWAN Cayenne LPP | 18-byte binary frame (alarm flag, anomaly score, RMS, Kurtosis) | Optional mode: uplink to ChirpStack / AWS IoT industrial dashboards |
Porting It to Your Own System
- Switchable to LoRaWAN: Flash the provided Cayenne LPP firmware via magnetic USB to connect with corporate ChirpStack gateways or TTN clusters.
- Bridge to SCADA / PLC: Connect any Meshtastic receiver node to a gateway PC via USB serial to forward mesh alerts into Node-RED, MQTT, or PLC networks.
- Rapid In-Field Recalibration: When machine rpm changes, simply reconnect to SenseCraft AI for 10 seconds to update baseline thresholds without reflashing firmware.
How to deploy
Check the setup and its product list, then follow the deployment guide.
Hardware Sizing & Deployment Setup
Select site conditions to generate recommended bundles and guides, or let an AI assistant estimate hardware and deploy for you.
Deployment Options
Off-Grid Mesh Communication
Out-of-the-box Meshtastic experience with T1000-E. Device comes pre-flashed; simply power on, pair via mobile Bluetooth, and test off-grid messaging and topology.
2 steps · ~15min
Meshtastic Tracker Node
sensecap_t1000e
FAQ
Foam tape acts as a vibration damper, absorbing high-frequency mechanical vibrations and distorting accelerometer measurements. Always use rigid, high-adhesion acrylic adhesive (such as 3M VHB 4910) for direct metal-to-plastic vibration transmission.
The system uses the open-source Meshtastic protocol over LoRa radio to form an ad-hoc mesh. Nearby personnel connect their smartphone to a portable T1000-E node via Bluetooth to receive instant popup alerts and buzzer notifications completely off-grid.
Under typical inspection cycles (sampling 1.5s every 10 minutes with an hourly heartbeat), the 700 mAh battery lasts 1 to 1.5 years. It is rechargeable via the included magnetic USB cable.
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