How many vibration sensors does one production line need?
A typical starting point is ten sensors and one gateway per production line, placed on the most critical machines first. Mount them where faults show up: both ends of each motor, the fan bearings and the pump drive end. One DHMSCare gateway connects up to 60 sensors, so you start on one production line and add sensors and lines as you grow.
Start from the machines, not the line
Count the machines whose failure would stop the line, then count the measuring points on each. Plans start from one sensor per machine, plus more where a machine has more measuring points, such as a gearbox or both ends of a large motor.
Each industry page lists the measuring points per machine, with a suggested sensor count for each row. The exact count depends on your layout, so treat those numbers as a starting plan.
Three common starting sizes
Most plants start with ten sensors and one gateway on a first line. A standard production line typically takes about 30–40 sensors. A whole plant is sized line by line, on the same template each time.
A ten-sensor first line is a real installation, not a demo. Your team sees how alerts and diagnosis reports arrive before you add the next line.
How gateways and range shape the layout
One DHMSCare gateway connects up to 60 sensors. Inside a plant, a sensor typically reaches the gateway from 60–80 m, depending on the walls and machines in the way.
Where the signal is weak, a DR100 repeater carries it past the obstacle. On a long or crowded line, plan the repeater positions together with the gateway.
Questions buyers also ask
Do small motors and pumps need more than one sensor?
Usually not. Small motors, pumps and fans often start with one sensor per machine, while gearboxes and large machines take one per measuring point.
Can we add sensors to the same gateway later?
Yes. One gateway connects up to 60 sensors, so you can add machines to it until it is full, then add a gateway for the next area.
Who decides where each sensor goes?
Your own team can place them with the Quick Installation Guide. If you are unsure, tell DHMSCare the machine type, its speed and where it is mounted, and DHMSCare recommends the sensor.